Corrosion resistant lubricants, greases, and gels

ABSTRACT

The disclosure relates to improved gel/grease compositions as well as grease compositions capable of imparting improved corrosion resistance. The grease includes a silica/silicate mixture that can imparts a relatively high pH and corrosion resistant properties to the grease.

The subject matter herein is a continuation-in-part of U.S. patentapplication Ser. No. 09/370,346, filed on Aug. 6, 1999 that is acontinuation in part of Ser. No. 09/130,790, filed on Aug. 7, 1998 nowU.S. Pat. No. 6,010,985 that is a continuation in part of Ser. No.09/045,450, filed on Mar. 20, 1998, now U.S. Pat. No. 6,017,857 that inturn is a continuation-in-part of U.S. patent application Ser. No.09/016,461, filed on Jan. 30, 1998 now U.S. Pat. No. 6,010,984 andentitled “Corrosion Resistant Lubricants, Greases and Gels”. The subjectmatter herein also claims benefit under 35 U.S.C. 111(a), 35 U.S.C.119(e) and 35 U.S.C. 120 of Provisional Patent Application Serial No.60/045,466, filed on May 2, 1997; and U.S. Provisional PatentApplication Serial No. 60/036,026, filed on Jan. 31, 1997; both of whichare entitled “Corrosion Resistant Lubricants, Greases, and Gels”. Thedisclosure of the aforementioned Provisional and Non-Provisional PatentApplications is hereby incorporated by reference.

FIELD OF THE INVENTION

The instant invention relates to improved grease compositions as well asgrease compositions capable of imparting improved corrosion resistance.

BACKGROUND OF THE INVENTION

The American Society for Testing and Materials (ASTM D288 standarddefinition of the terms relating to petroleum) defines a lubricatinggrease as a solid to semi-fluid product of dispersion comprising athickening agent and a liquid lubricant. Other ingredients impartingspecial properties may be included. This definition indicates that agrease is a liquid lubricant thickened in order to provide propertiesthat are not provided solely by the liquid lubricant. Typically, greasesare employed in dynamic rather than static applications. Gels arenormally classified as a colloid and provide utility in non-dynamicapplications ranging from sol-gels to cosmetic applications.

Conventional grease formulations are described in “Synthetic Lubricantsand High-Performance Functional Fluids”, edited by Ronald L. Shubkin(dated 1993). The characteristics of soap based greases, additives andmethods for making conventional greases are described in “The Chemistryof Soap Base Greases” by Glen Brunette, “Additives For Grease”, by Dr.Miles Hutchings and “Grease Manufacture in Conventional Kettles” by K.F. Montgomery all of which were presented at the 63rd NLGI AnnualMeeting, October 1996. The disclosure of the previously identifiedpublications is hereby incorporated by reference.

Commercial industrial practice employs lubricating films and greases toprevent galling and fretting. The increased efficiency and complexity ofmodern machines often require such films and greases to perform undersevere operating and environmental conditions. While the composition ofa gel may be similar to a grease, typically gels are employed to solvenon-lubricating problems. There is a need in this art for lubricants,greases and gels that also impart corrosion resistance.

SUMMARY OF THE INVENTION

The instant invention solves problems associated with conventionallubricants and greases by providing an improved composition whichimparts corrosion and microbial resistance, and a high dropping point.By “dropping point” it is intended to mean the temperature at whichlubricating compositions become fluid and thereby able to drip throughan orifice in accordance with ASTM D2265. The inventive grease typicallyhas a minimum dropping point of about 250° C.

The instant invention also provides a composition that can offer analternative to conventional greases and gels thereby also avoiding theenvironmental and manufacturing problems associated with conventionalgrease products. The inventive greases and gels can be tailored to rangefrom microbial resistant to biodegradable; but in either case thegreases/gels are non-toxic. By “non-toxic” it is meant satisfying thestandards for toxicity set forth in ASTM E-729-88a. While the instantinvention is compatible with a wide range of metals and metalliccoatings, the instant invention can also obviate the usage ofenvironmentally undesired metals, e.g., chrome, that are conventionallyemployed for imparting corrosion resistance. Similarly, while theinstant invention can be employed with a solvent, in certain aspects theinventive grease/gel can be solvent free or substantially solvent free.By “substantially solvent free”, it is meant that the grease/gelcontains less than about 30 wt. %; and normally less than 10 wt. %, ofvolatile organic compounds (otherwise known as V.O.C.s). By “solventfree” it is mean that the grease/gel contains less than 5 wt. % andnormally less than 1 wt. % of volatile organic compounds (V.O.C.s).

The inventive grease/gel can be employed as a substitute forconventional greases/gels; especially in environments where improvedcorrosion resistance is desired, e.g., wire rope and strand that is usedin a wide range of applications including automotive and marineend-uses. Further, the inventive grease/gel can be employed forreducing, if not eliminating, corrosion under insulation (CUI). That is,corrosion upon metallic surfaces which are covered by an insulatingcovering or layer, e.g., a mechanically attached insulating sleeve upona pipe. CUI is particularly problematic in the petroleum industrywherein corrosion can occur under refinery pipes, cracking columns,oil/gas pipelines, reaction vessels, among other areas. Corrosion underinsulation can also occur in heating ventilation and cooling (HVAC)water lines, steam lines for chemical processing and power generation,conduits/piping on ships, among other areas. In addition, the inventivecompositions can improve resistance to stress crack corrosion, amongother benefits.

The instant invention can also offer an alternative to siliconecontaining lubricants. For example, in automotive painting environmentssilicone oils have been associated with adverse affects, e.g., on thequality of painted surfaces due to low molecular fractions of thesilicone becoming air-borne under ambient conditions. The instantinvention, however, can improve the corrosion resistance of siliconcontaining lubricants and gels.

The inventive grease/gel can also be employed upon chains, gears,pulleys, wire rope or strand for end-uses in automotive, industrial,marine cables, among other uses. The inventive grease/gel can beemployed to protect pipe flanges. For example, a carbon steel pipeflange connected by carbon steel bolts can be protected by applying theinventive grease/gel upon and within the flange, and wrapping the flangewith a tape, e.g., aluminum, fiber reinforced, typically with anadhesive. The flange wrap can be affixed by using any suitable fasteningmeans such as metal bands, clamps, adhesives, among others.

The fluid or liquid portion of the inventive grease/gel can comprise abase oil comprising at least one member selected from the groupconsisting of mineral oil, synthetic oil, vegetable oil, fish oil,animal oil among any suitable fluid having lubricating properties.Examples of suitable base oils include at least one member from thegroup consisting of animal, vegetable, petroleum derived and syntheticoils such as polyalphaolefin (PAO), silicone oil, phosphate esters,fluorinated oils such as KRYTOX (supplied by the DuPont Company,Wilmington, Del.), mixtures thereof, e.g., a base oil comprising amixture of vegetable and synthetic oils, among others. Typically, thebase oil will comprise about 45 to about 90 wt. % of the grease e.g.,about 70 wt. % to about 90 wt. %.

Environmentally preferred lubricants (EPL's) are preferred as base oilsin applications where loss of material to the environment can occur.EPL's have the distinction of being biodegradable and/or essentiallynon-toxic. Biodegradable base oils include, but are not limited to fishoils, vegetable oils, lanolin, synthetic esters, low molecular weightpolyalfaolefins, and polyalkylene glycols. Essentially non-toxic baseoils include but are not limited to polyalfaolefins, polybutenes,vegetable oils and also lanolins. Examples of suitable vegetable baseoils comprise at least one member from the group consisting of rapeseedoil, canola oil, soybean oil, corn oil, cottonseed oil, linseed oil,olive oil, tung oil, peanut oil, meadowfoam oil, sunflower oil,safflower oil, jojoba oil, palm oil, castor oil, among others. Thevegetable base oil can be obtained from a genetically modified plant orbe modified by water washing, refining, esterification, hydrolysis,etc.; thereby producing an oxidation resistant base oil e.g. high oleicsoybean oil.

For applications requiring that the grease be exposed to a relativelyhigh or low temperature, or wide variation in temperature duringoperation, synthetic fluids are typically employed, e.g., a diester oilbased grease. If the grease comprises a metallic soap grease, thencomplexing agents can be employed for improving the so-called “droppingpoint” of the grease. Such agents are usually present in an amount fromabout 5 to about 25 wt. % of the grease.

A thickener is combined with a base oil to form a grease or gel. Thethickener component of the grease can comprise any material that incombination with the selected base oil will produce a semi-fluid orsolid structure. Examples of a suitable thickener comprise at least onemember selected from the group consisting of soaps of aluminum, lithium,barium, sodium, calcium, mixtures thereof, and, in some cases, silicasand clays, mixtures thereof, among others. Characterization of grease asa function of the thickener is described in greater detail by J. GeorgeWills in “Lubrication Fundamentals” (1980); hereby incorporated byreference. Thickeners of differing composition can be blended together,e.g., TEFLON fluoropolymers and polyethylene, provided they arecompatible with one another and with the base oil. Additionalingredients can be combined with the thickener to impart specialfeatures or properties such as coupling agents dyes, pigments,anti-oxidants, among other components for tailoring the properties ofthe grease. Normally, the thickener will comprise about 5 to about 10wt. % of the grease, and additional ingredients will comprise a totalamount of about 5 to about 30 wt. %. However, when thermoplasticpowders, for example, polytetrafluoroethylene, polyethlene and the like,are used as thickeners can be used effectively in amounts up to about50% by weight.

The inventive grease can also comprise at least one anti-wear agentwhich may also function as a pour-point depressant, and/or an extremepressure agent. Examples of suitable anti-wear agents comprise at leastone member from the group consisting of tricresyl phosphate,dithiophosphates, fatty acid esters, metal stearates, zinc oxide, borax,boron nitride, ammonium molybdate, calcium carbonate, mixtures thereof,among others. In some cases, molybdenum disulfide, polyethylene,polytetrafluoroethylene, polyvinylidene fluoride/polyvinyl fluoride anddispersions thereof; mixtures thereof, among others, can be added toreduce friction and wear. Anti-wear agents can comprise about 0.1 toabout 2 wt. % of the grease. Examples of extreme pressure agents cancomprise at least one member selected from the group of graphite,triphenyl phosphorothionate, chlorinated parafins, dithiocarbonates,fatty oils, fatty acids, or fatty acid esters with a phosphite adduct;sulfurized fatty oils, fatty acids, or fatty acid esters; molybdenumdisulfide, tungsten disulfide, phosphate esters, phosphorous-sulfurcontaining compounds, mixtures thereof, among others. Powdered extremepressure agents can protect rough or uneven surfaces as well as taperedcrevices when the agents are composed of a sufficiently wide particlesize distribution and with an appropriate limit on the maximum particlesize. The particle size distribution would normally allow the EP agentto fill in gaps and spaces upon the article to be protected (such asexist in wire rope, stranded cable, or armored cable). Extreme pressureagents can comprise about 2 to about 10 wt. % of the grease.

Surfactants, wetting agents, or surface active agents can optionally beincluded when desirable, such as pine oil and derivatives. Tall oil andderivatives, ethoxylates, acetylenic diols, silicones, silanes,sulfonates, fluorosurfactants, mixtures thereof, among others.

The inventive grease can further comprises at least one of silica and/ora silicate containing component for imparting corrosion resistance,e.g., a component containing —SiO— groups. The silicate containingcomponent can interact with another component of the grease and/or asurface being protected. The interaction can provide a protectivesurface having enhanced corrosion resistance. The amount ofsilica/silicate containing material can range from about 1 to about 50wt. % of the grease. The specific amount of silicate containing materialis ascertained when considering the relative importance of corrosionresistance and lubrication for a particular application as well as thethickening ability of the silica or silicate.

In some cases, it is desirable to utilize a gel with less potential foroil to migrate out of or separate from the gel. Drying oils, e.g.,linseed, or non-drying polymers can be added to the gel to reduce oilloss or migration from the gel. Polymers include but are not limited topolyurethane, silicone, acrylic, epoxy, oil modified polymers, andvegetable oils, e.g., an epoxidized vegetable oils. High solids polymersor substantially solvent free polymers are environmentally preferred,e.g., polymers containing less than about 30 wt. % V.O.Cs.

In other cases, it is desirable for the gel to form an outerself-supporting layer or skin. The portion of the gel underlying theself-supporting layer can remain in a substantially unchanged state,e.g., the retained physical characteristics of the underlying portionresemble those of an newly applied gel coating. If desired, the entirethickness of the grease/gel can be cured. The self-supporting layer canbe achieved by including a UV activated catalyst. Examples of suitablecatalyst are disclosed in WO 98/53008 and U.S. Pat. Nos. 4,892,894 and4,308,118; the disclosure of which is hereby incorporated by reference.An added benefit of forming a self-supporting layer or so-called skin atthe surface of the gel is that the layer provides improved resistance torainwater and incidental contact. If desired the self-supporting layercan be painted by using conventional methods.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a graphical representation of steel corrosion when underinsulation in terms of Time v. Corrosion Rate (mills per year-mpy).

CROSS REFERENCE TO RELATED PATENTS AND PATENT APPLICATIONS

The subject matter of the instant invention is related to copending andcommonly assigned Non-Provisional U.S. patent application Ser. No.09/016,853 (Attorney Docket No. EL001RH-8), filed on Jan. 30, 1998; Ser.Nos. 08/850,323 and 08/850,586 (EL001RH-6 and EL001RH-7 filed on May 2,1997); Ser. No. 08/791,336 (Attorney Docket No. EL001RH-5 filed on Jan.31, 1997) and 08/791,337 (Attorney Docket No. EL001RH-4 filed on Jan.31, 1997) in the names of Robert L. Heimann et al., as a continuation inpart of Ser. No. 08/634,215 (Attorney Docket No. EL001RH-3 filed on Apr.18, 1996) in the names of Robert L. Heimann et al., and entitled“Corrosion Resistant Buffer System for Metal Products”, which is acontinuation in part of Non-Provisional U.S. patent application Ser. No.08/476,271 (Attorney Docket No. EL001RH-2 filed on Jun. 7, 1995) in thenames of Heimann et al., and corresponding to WIPO Patent ApplicationPublication No. WO 96/12770, which in turn is a continuation in part ofNon-Provisional U.S. patent application Ser. No. 08/327,438, now allowed(Attorney Docket No. EL001RH-1 filed on Oct. 21, 1994).

The subject matter of the instant invention is also related to copendingand commonly assigned Non-Provisional U.S. patent application Ser. No.09/016,849 (Attorney Docket No. EL004RH-1), filed on Jan. 30, 1998 andentitled “Corrosion Protective Coatings”.

The disclosure of the previously identified patent applications andpublications is hereby incorporated by reference.

DETAILED DESCRIPTION

A lubricating grease is defined by National Lubricating Grease Institute(NI.GI) as “a solid to semifluid product of dispersion of a thickeningagent in a liquid lubricant. Additives imparting special properties maybe included”, e.g., refer to the Lubricating Grease Guide, 4th ed.;NLGI; Kansas City, Mo.; p.1.01; the disclosure of which is herebyincorporated by reference. For purposes of this invention, the termsgrease and gel are used interchangeably wherein the term varies as afunction of its application, e.g., dynamic greases or static gels.Typically, greases and gels fall broadly within the following formula:

Base oil 45-90% Thickener  5-25% Additives  1-30%

In an aspect of the invention, the inventive composition can comprise agel which forms a self-supporting outer layer or skin. This type of gelhas the capability of forming an outer layer or skin for the purpose ofproviding improved characteristics such as a tack-free gel surface andresistance against washing away by rain or immersion. The outer skin canbe achieved by any suitable means such as adding cross-linking polymersto the inventive composition. Examples of desirable methods forachieving cross-linking in the inventive composition include: 1)employing drying oils that exhibit an oxidative type curing mechanism,2) by utilizing a moisture curing mechanism, 3) reactive cure, 4)catalytic or non-catalytic ultra-violet (UV) cure, 5) heat curingmechanism, among other chemistries. Examples of suitable UV curablecatalyst (also known as photo-initiators) comprise acetophenoe,phosphene oxide, onium salts such as a sulfonium salt, mixtures thereof,among others. Depending upon the chemistry and environment, the selectedmethod can be employed to obtain results that range from forming aself-supporting layer to hardening the entire inventive composition. Thethickness of the self-supporting layer can be tailored by adding one ormore UV absorbers, e.g., hydrogen abstraction or alpha cleavage, to thecomposition. Examples of UV absorbers comprise TiO2, ZnO, among otherpigments. Normally, the self-supporting layer is about 0.001 to about0.05 inch thick depending on application.

A cross-linking polymer system can be added to any base oil so long asthe polymer to be crosslinked is partially miscible in the base oil, thecrosslinked layer or hardened composition is resistant to the base oiland the system is compatible with the remaining components of theinventive composition. Examples of suitable base oils include at leastone member from the group of naphthenic and paraffinic mineral oils, andsynthetic oils such as polyalfaolefins, silicones, phosphate esters,fluorinated oils, polybutenes, polyalkylene glycols, alkylatedaromatics, among others. Conventional drying oils can also be used toform a self-supporting layer or skin, e.g., linseed oil, and theoxidative curing can be accelerated by metallic catalysis such as cobaltnaphthenate. Polymers such as oil modified epoxies or polyurethanes mayalso be utilized, e.g., Ketimine type moisture curing epoxy resin. Whilethe amount of cross-linking polymer can be tailored to obtain thedesired affect, typically the polymer corresponds to about 0.010 to lessthan about 50 wt. % of the inventive composition, depending oncompatibility between the polymer and the gel base oil. At loadingsgreater than 50% the composition becomes increasingly like the polymeritself and gel-like characteristics decrease.

In another aspect of the invention, the physical characteristics of thegel as applied are retained for an extended period, e.g., the gel issubstantially non-crosslinked or lacking a self-supporting layer. Inthis aspect of the invention, the base oil of the grease/gel cancomprise a polymer such as a polyurethane or an epoxy and an oil such aslinseed or a drying oil. Without wishing to be bound by any theory orexplanation, it is believed that employing a relatively large amount ofoil inhibits crosslinking in the polymer thereby causing the gel toretain its as applied characteristics.

Moreover, the previously described polymer/drying oil combination can beemployed as components in a non-toxic oil based gel, e.g., based uponpolybutene, polyalphaolefin, lanolin, mixtures thereof, among others.The polymer component of the inventive composition serves to improve thecomposition's adhesion and/or cohesion to a metal surface. Withoutwishing to be bound by any theory or explanation, it is believed thatthe drying oil component, e.g., linseed oil, forms a reticulating orinterpenetrating network among the oil and polymer components of theinventive composition. While this aspect of the invention can beemployed in a wide of end-uses, this aspect of the invention isparticularly useful in reducing pipe corrosion under insulation. Ifemployed under pipe insulation, clean up or removal of the compositioncan be achieved by using commercially available citrus-based cleaners.

The pH of the grease can be tailored to be compatible with the metalsurface which is contacted with the grease or gel. That is, certainmetals and alloys can become susceptible to caustic cracking whenexposed to a relatively high pH, e.g, about 10 to about 14. In suchcases, it may be appropriate to employ an alkali silicate such as sodiumsilicate with another silicate such as calcium silicate. Without wishingto be bound by any theory or explanation, the mechanism of protectionfollows the laws of chemical absorption and chemical affinity when thegrease or gel contacts the surface being protected. The inventive greasewill typically have a pH that ranges from about 7 to about 14. It isalso believed that the presence of a relatively high pH in the greasecan hydrolyze, for example, zinc borate and silica, and equipotentializethe surface being protected. Depending upon the composition of thegrease or gel and surface being protected, one or more components of thegrease or gel can react with each other and/or the underlying surface toform a protective layer or film, e.g., when the inventive grease or gelis applied to a zinc containing surface a unique surface comprising analkali zinc silicate crystallites within an amorphous phase compositioncan form.

Normally, a silicate will be employed as a thickener as well as acorrosion inhibitor. The silicates used for preparing the inventivegrease/gel that is employed in lubricating applications such as workingwire ropes are normally finely ground by milling the raw material or thefinal composition, e.g., milled to a particle size of about 1 to about20 microns and in some cases less than 200 mesh. Suitable silicates forworking wire ropes among other applications can be selected from thegroup consisting of aluminum silicate, magnesium silicate, sodiumsilicate, calcium silicate, potassium silicate, lithium silicate,ammonium silicate, (each with various amounts of moisture of hydrationand various ratios of silica to cations such as Na+, NH4, among others),mixtures thereof, among others, and can be mixed together by anysuitable means. The aforementioned silicates can be combined with or, insome cases, replaced by molybdates, phosphates, zirconates, titanates,vanadates, permanganates, pertechnetate, chromate, tungstate, nitrate,carbonates, aluminates, ferrates, mixtures thereof among others. To thissilicate mixture, can be added at least one of a surfactant, couplingagent and at least one dispersion oil that are compatible with the baseoil of the grease, e.g., silicone oil PAO or polybutene, thereby formingan intermediate product. Typically, the coupling agent will compriseabout 0.1 to about 2 wt. % of the grease and can be at least one memberselected from the group consisting of organotitanates, organozirconates,organoaluminates and organophosphates. Surfactants include ethoxylates,pine oil, pine oil derivatives, tall oil, tall oil derivatives,acetylenic diols, long chain fatty acids, sulfosuccinates, alkylsulfates, phosphates, sulfonates, long chain amines, quaternary ammoniumcompounds, organosilicons, fluorinated surfactants, mixtures thereof,among others. A suitable dispersion oil can be at least one member fromthe group consisting of linseed, boiled linseed, castor, canola,mineral, olive, peanut, sunflower, corn, soybean, cedar, pine, coconut,tung, vegetable, rapeseed, olive, jojoba, lanolin, meadow foam,cottonseed, sesame, palm, mixtures thereof, among others, and normallycomprise about 1 to about 40 wt. % of the grease. In the case oflanolin, the amount of dispersion oil normally corresponds to about 5 toat least 10 wt. %.

The previously described intermediate product can be dispersed or mixedwith the remaining components of the grease, e.g, base oil, extremepressure additive, among others. By adding the intermediate product tothe remaining components, a corrosion resistant grease is obtained.

The aforementioned inventive intermediate product can be introduced intoany suitable type of grease or gel such as:

1) Soap-Thickened Greases/Gels

 Aluminum Soap Grease

 Hydrated Calcium Soap Grease

 Anhydrous Calcium Soap Grease

 Sodium Soap Grease

 Lithium Soap Grease

2) Soap-Complexed Greases/Gels

 Aluminum Complexed Grease

 Calcium Complexed Grease [the amount of alkaline silicates that can beadded to calcium complexed grease is relatively low in comparison toother greases]

 Barium Complexed Grease

 Lithium Complexed Grease

3) Non-Soap Greases/Gels

 Mineral Oil Based Grease

 Vegetable Oil Based Grease

 Organo-Clay Grease

 Polyurea Grease

 Polyurea Complexed Grease

The thickener utilized in the soap-based greases is typically asaponification reaction product that is generated during thegrease-making process. The saponification reaction can occur among atleast one of the following components long-chained fatty acids, e.g.stearic acid, oleic acid, among others; fat, e.g., beef tallow; and analkali component, e.g., aluminum, calcium, sodium, lithium hydroxide,among others. The aforementioned alkali component is normally used in aslight excess to facilitate driving the saponification reaction and toneutralize any remaining free acid. As the saponified product is cooled,the product can form a fibrous network through the base oil, e.g., amineral or hydrogenated castor oil, thereby thickening the grease. Forbest results, the fatty acid or fat component is compatible with thebase oil, the appropriate amount of thickener is employed, and thesaponification reaction occurs at relatively dispersed locations withinthe base oil. For example, the aforementioned fibrous network may not beadequate if the saponification is conducted separately and then mixedinto the base oil. Finally, the rate of cooling and amount of waterpresent can impact the fibrous network formation rate.

A soap complexed grease is similar to the soap-thickened grease in thatboth types of greases rely upon the saponification reaction. However,the soap complexed greases have an additional reactant which becomes acomponent of the saponified product and facilitates forming the fibrousnetworks. The complexing or chelating reactant is normally a metal saltof a short chained organic acid, e.g., a calcium acetate, or a metalsalt of an inorganic acid, e.g., lithium chloride. (The grease may alsocontain aluminum atom(s) which were part of the organic soap molecules,e.g. aluminum distearate and aluminum hydroxide) Total thickenercontents, respectively, of the calcium, aluminum, and lithium complexgreases are about 25 to about 35 wt. %, about 5 to about 9 wt. %, andabout 12 to about 18 wt. %. In one aspect of the invention, thethickening soap may comprise sulphurized-phosphorized lard oil inlithium grease. This thickening soap can also function as an extremepressure additive within the grease.

Non-soap based greases do not require the previously describedsaponification reaction to thicken the grease. Non-soap greases employphysical additives for thickening. While any suitable thickener can beemployed, an example of a suitable thickener is organo-clay particles,or platelets of small organic or inorganic particles dispersed withinthe base oil. Further examples of thickeners comprise at least one ofbentonite clay, fumed silica (aerogel), carbon black, powdered plastics,gilsonite, mixtures thereof, among others. In addition, surface modifiedthickeners may also be utilized. Normally, the thickener has a largesurface area and typically a certain amount of an oil absorptioncapability.

Polyurea and polyurea complexed greases are related to the soap basedgreases in that reactions polymerize component materials, e.g.,isocyanates and amines, to form the thickener, e.g., polyurea. However,the polyurea normally does not form fibrous networks to the extent ofsoap based greases. The complexed polyureas utilized the same types ofcomplexing agents as the complexed soap based greases.

The following types of additives may be incorporated into greases orgels to achieve a variety of desired properties: rust inhibitors,antioxidants, soaps, odor modifiers, tackiness agents, structuremodifiers, metal deactivators or corrosion inhibition for non-ferrousmetals, solid lubricants (such as graphite, zinc oxide, borax, amongother conventional solid lubricants), phosphate esters,polytetrafluoroethylene, dithiophosphates, dithiocarbonates,antimicrobial agents, mixtures thereof, among other suitable additives.Examples of suitable rust inhibitors comprise at least one memberselected from the group consisting of fatty acids, sulfonates, amines oramine phosphates, amides of fatty acids, succinates, benzotrizoles,tolutriazoles, mercaptobenzothiazole, thiadiazoles, metal carboxylates,mixtures thereof, among others. Examples of suitable antioxidantscomprise at least one member selected from the group consisting ofaromatic amines, hindered phenols, diphenylamine, phenylalpha-naphthylamine, 2,6-di-t-butylphenol, phenothiazine, alkylateddiphenylamines, alkylated phenyl alpha-naphthylamines,2,6-di-t-butyl-p-cresol (BHT), polymeric BHT, peroxide decomposers,vitamin C (ascorbic acid), vitamin E (alpha tocopherol) and derivativesthereof such as sodium ascorbate, alpha tocopherol acetate); mixturesthereof, among others to inhibit natural or high temperature oxidationof the composition. The formulation can also include additives toimprove ultraviolet (UV) light stability such as Tinuvin (Ciba Geigy), asubstituted hydroxyphenyl benzotriazole. Examples of soaps includelithium stearate, aluminum stearate, calcium stearate, or zinc stearate.Soaps may be utilized to impart added lubricity, heat resistance, ormoisture resistance. Examples of suitable tackiness agents comprise atleast one member selected from the group consisting of high molecularweight hydrocarbons, rubber latex, polybutenes, estergums and terpeneresins mixtures thereof, among others. Examples of suitable structuremodifiers comprise at least one member selected from the groupconsisting of glycerol, alcohols, glycols, fatty acids, water, alkalisufonaphthenates, mixtures thereof, among others. Examples of suitableanti-microbial agents comprise at least one member selected from thegroup consisting of d'limonine, zinc borate, silver, quaternary ammoniumcompounds, mixtures thereof, among others. Other environmentally lessdesirable anti-microbial compounds include compounds of mercury, tin,antimony, and mixtures thereof. The additives can also comprise at leastone member selected from the group consisting of surfactants, wettingagents, surface active agents, pine oil, derivatives, tall oil andderivatives, ethoxylates, acetylenic diols, silicones, silanes, fattyoils or acids with a phosphate adduct, sulfurized fatty oils, molybdenumdisulfide, tungsten disulfide, mixtures thereof, among others. The totalamount of these additives normally does not accumulate to more thanabout 5 wt. % of the total grease formulation. The inventive compositioncan also include a substance for imparting conductivity to thecomposition such as graphite carbon, conductive polymers, metal powderor flake mixtures thereof, among others. The amount of conductivecomponent normally ranges from about 15 to about 45 wt. % of theinventive composition.

While the inventive grease/gel can provide a physical barrier from acorrosive environment, the grease can also supply a silica/silicateproduct that imparts the previously described corrosion-inhibitingproperties. Depending upon the composition of the metal surface,composition of grease/gel applied to the surface, temperature and lengthof time the composition is in contact with the metal surface, surfacepH, at least a portion of the grease can interact with the metalsurface. The interaction can produce a mineral-like surface coating,e.g, less than about 100 Angstroms thick, characterized by uniquecrystallites, e.g, an alkali zinc silicate, within an amorphous matrix.A more detailed description of mineral layers and precursors thereof canbe found in the aforementioned copending and commonly assigned U.S.Patent Applications; the disclosure of which was incorporated byreference.

While the inventive grease can be employed in connection with avirtually unlimited array of surfaces, desirable results have beenobtained when the grease is employed upon a zinc containing surface oralloy. The inventive grease can be employed in a virtually unlimitedarray of applications such as upon pipe in order to inhibit corrosionunder insulation, wipe rope and strand products during manufacture orafterwards by injecting the grease, and applied to the exteriorarmor/sheathing of electrical and optical fiber cables that are exposedto marine environments as well as mechanical force cables such as thoseemployed in automobiles, boats and aircraft. The invention is alsouseful in cable applications where RFI-EMI properties are important suchas some undersea cables. The inventive grease can also be employed ascutting/buffing/grinding fluids for ceramics/metals, protect andlubricate lead alloy battery terminals, protect and lubricate lockassemblies, and protect coiled metal rolls or stack metal sheet fromcorrosion, among many other applications where corrosion resistanceand/or lubrication are useful. The inventive greases or gels can beemployed in single or multiple layers having chemically similar ordistinct chemical compositions e.g., employing one composition as apre-coat or primer for another composition. The inventive greases orgels can also be protected by any suitable outer covering such as amastic tape or wrap, fiberglass batting, lagging, films (e.g., Mylar®,aluminum, etc.), among others. The outer covering can impart improvedresistance to impact, UV radiation, water erosion, among other chemicalor physical agents.

The inventive greases or gels can be applied to the above users viaspray, trowel, glove, brush, immersion, pressure injection, or pumping.Normally, for spraying the grease/gel is combined with a diluent such asat least one solvent selected from the group consisting of isopropanol,reagent alcohol, naphta, dimethyl ether, methyl ketone, mineral spirits,e.g., about 10 to about 20 wt. % diluent and normally about 12 to about14 wt. %, among other commercial solvents such as that supplied asEnsolve®. Different combinations of diluents can be used for tailoringsmoothness, sag of material, bubbles, sponginess, among otherproperties. If desired, before applying the inventive grease/gel upon asurface the surface can be pretreated, e.g., by applying a coatingcomprising at least one of PAO or polybutene oil. After being appliedupon a surface (with or without a pretreatment), at least a portion ofthe applied inventive greases/gels can be modified for improvingmoisture resistance as well as impart other improved properties. Anexample of a modification method comprises heating the appliedgrease/gel to form an exterior skin or layer.

The inventive greases or gels can also be applied via an aerosol spray.The inventive greases or gels are combined with the aforementioneddiluents and a suitable propellant. Examples of suitable propellantscomprise one or more of fluorocarbons such as HFC-134, IIFC-134a,IIFC-152 a, among others; hydrocarbons such as alcohol, butane,isobutane, polybutene, propane, isopropane, dimethylether and isomersthereof; commercially available propellants such as A-31, A-46, amongothers; carbon dioxide, mixtures thereof, among others. The ratio ofgrease or gel to propellant is normally about 1:1; but the ratio canvary widely to achieve a desired viscosity or application depth. Thedispensing characteristics.

The following Examples are provided to illustrate not limit the scope ofthe invention as defined in the appended claims. The weight percentranges in certain examples are present to due variations in mixingconditions, retention in mixing apparatus, among other conventionalmanufacturing variations.

EXAMPLE 1

The formulation listed below in Table 1 was produced by adding powderedmaterials to the PAO base oil, i.e., polymerized 1-decane. The PAO oilwas poured into a 1 quart stainless steel bowl. The powdered materialswere then added to the PAO and mixed by hand.

TABLE 1 COMPONENT SUPPLIER AMOUNT % BY WT. PAO base oil Nye Lubricants53.5% Silica Nye Lubricants 9.8 G Sodium silicate PQ Corp. 30.0 ZincBorate U.S. Borax 5.0 p-Hydroxy Aniline Mallinckrodt Chemical 0.7 IndigoBlue Dye Tricon Colors Inc. 1.0

This composition, when applied to a standard ACi electrogalvanized steeltest panel (E60 EZG 60G 2 side 03×06×030) to a thickness of {fraction(1/16)} inch, protects from red corrosion for a minimum of 1000 hours inaccordance with ASTM B117 salt spray exposure. When the composition wasremoved from the panel after a minimum of 24 hours by carefully scrapingoff the excess and then washing with naphtha, an average of 192 hours ofASTM B117 salt spray exposure was obtained prior to the appearance ofred corrosion products compared to 120 hours for untreated controlsamples.

Depending upon the surrounding environment, improved corrosionresistance can be obtained by omitting p-Hydroxy Aniline. Further, thecorrosion resistance of a PAO based grease or gel can be improved by theadding at least one of sodium molybdate, sodium carbonate, and sodiumsilicate.

EXAMPLE 2

A second formulation substantially the same as that described in Example1 was prepared with the exception that p-Hydroxy Aniline was omitted.The removal of the p-Hydroxy aniline improved the environmentalacceptability of the formulation without adversely impacting thecorrosion resistant properties of the grease.

A third formulation was prepared by omitting the zinc borate. Whilesilica was employed as a thickener, e.g., refer to the Standard BaseFormulation in Table 2 below, the presence of silica and a silicate canhave a desirable combined effect upon the corrosion resistant propertiesof the grease. Zinc borate functions as a fire retardant and amicrobiological inhibitor and, therefore, can be removed with itsattendant properties.

EXAMPLE 3

The following formulas were produced to compare the corrosion resistanceof the inventive greases to a base formulation.

TABLE 2 AMOUNT COMPONENT SUPPLIER (WT %) BASE FORMULATION PAO Durasyn174 (Amoco Oil Co.) 88.4% silica Cabosil TS720 (Cabot Corp.) 11.1% dyeT-17N Dye (DayGlo Color Corp)  0.5% CORROSION RESISTANT FORMULATION 1PAO Durasyn 174 (Amoco Oil Co.) 57.3% PAO Durasyn 166 (Amoco Oil Co.)14.3% silica Cabosil TS720 (Cabot Corp.)  7.3% zinc borate Borogard ZB(U.S. Borax)  4.1% sodium silicate G Grade (PQ Corp.) 16.3% indigo bluedye Tricon Color Corp.  0.7% LUBRICANT FORMULATION 1 PAO Durasyn 174(Amoco Oil Co.) 58.4% polytetrafluoroethylene Fluro 300 (Micro PowdersInc.) 40.9% indigo blue dye Tricon Color Corp.  0.1% organo zirconateKen-React NZ-12 Kenrich  0.6% Petrochemical, Inc. CORROSION RESISTANTFORMULATION 2 silicone oil Dow Corning 200   75% silica Cabosil TS729(Cabot Corp.)   15% sodium silicate G grade (PQ Corporation)   10%

Corrosion Formulation 1 was prepared by mixing the zinc borate andsodium silicate together in a manner described in Example 1. Theborate/silicate blend was added to Durasyn 166 PAO. The silica was mixedwith Durasyn 174 PAO. The two PAO mixtures were then combined. The dyewas then added to the combined PAO mixtures.

Lubricative Formulation 1 was prepared by first treating the Fluoro 300with a 2.3 weight % solution of NZ-12 in 2-propanol, and allowing the2-propanol to evaporate. The treated Fluoro 300 was then mixed into theDurasyn 174 by hand. After thorough mixing, the Indigo blue dye asintroduced. While both Formulations have a wide range of uses,Lubricative Formulation 1 is particularly useful as an emergency or aparking brake cable lubricant.

Corrosion Formulation 2 was formed substantially in the same manner asCorrosion Resistant Formulation 1. If desired, the sodium silicate ofthe previously identified Formulations can be mixed with or substitutedfor calcium silicate, trisodium phosphate, sodium bicarbonate, amongothers, in order to obtain a grease/gel with a lower pH. Further, ifdesired the sodium silicate can be at least partially replaced bypolytetrafluoroethylene to improve its lubricative properties.

EXAMPLE 4

corrosion Resistant Formulation No. 1 was coated upon a standard ACTelectrogalvanized steel test panel (1:60 EZG 60G 2 side 03×06×030) byapplying an excess and smoothing with a gate type applicator to leave a1/16 inch thick layer. The grease/gel remained in contact with the testpanel for a period of about 24 hours. The grease/gel was removed fromone-half of the test panel by light scrapping and washing with naphtha.

The test panels were then tested under a salt spray environment inaccordance with the ASTM Procedure B117. The area where the coating hadbeen removed lasted about 216 hours before 5% of the surface area wascovered with red rust. The grease/gel coated area of the test panel hadno visible red rust after 1,000 hours of salt spray exposure.

EXAMPLE 5

The following formula was prepared and applied to an outdoor aboveground piping which was subsequently covered with an external layer ofinsulation.

COMPONENT SUPPLIER AMOUNT Polyalfaolefin Base Durasyn 174/Amoco Oil Co.81.7 wt. % Oil Silica Cabosil TS-720/Cabot Corp. 4.7% Synthetic CalciumHubersorb 600/J. M. Huber Corp. 11.7% Silicate Polybutene Based IdaTacM256/Ideas, Inc. 1.5% Tackifier Dye Indigo/Tricon Color Corp. 0.4%

The Hubersorb 600 and Cabosil TS-720 were dry mixed together in acovered 5 gallon pail for 5 minutes and then the mixed composition wasadded to the Durasyn 174 base oil in successive additions until all thepowder had been added. The resulting mixture was then mixed for anadditional 20 minutes.

After combining the Durasyn, IdaTac M256 was added volumetrically from asyringe and mixing was continued for 15 minutes. Finally, the Indigo dyewas added and the composition was mixed for an 15 additional minutes.

The final composition had a penetration number of 317 as determined inaccordance with ASTM-D217. The resulting composition was applied to astandard cold roll steel panel in a clean/unpolished condition to obtaina film thickness of {fraction (1/16)} inch. After 24 hours of exposureto salt spray in accordance with ASTM B-117 no corrosion had occurredbeneath the film.

The composition was also applied to a rusted 2.5 inch diameter steelpipe that had been wire brushed to remove loose scale. The film wasapplied to approximately {fraction (1/16)} thickness and the pipe wasnot covered with insulation. After 4 weeks of outdoor exposure(including rain and wind events) no noticeable degradation, or less ofcoated material from the pipe was observed.

EXAMPLE 6

The above formulation for CUI application is adapted for use on anautomotive/industrial battery terminal to control the corrosion ofbattery posts. A battery terminal corrosion protectant is prepared byremoving the indigo dye and adding up to about 30% by weight conductivecarbon black to the aforementioned composition, (the conductive materialwill provide a dark color).

EXAMPLE 7

Amounts of Cabosil TS-720, Hubersorb 600, Lithium Hydroxystearate,S-395-N5 and Ackrochem 626 were measured out in quantities sufficient toprepare a 350 g. total batch. These powders were then dry mixed and thenadded to the Lubsnap 2400 oil which had been preheated to 110° C. Thecomposition was then mixed with a Premier Mill Series 2000 Model 84Laboratory Dispersator at N3000 rpm utilizing a 2-inch ZNOCO Desrondispersion blade for 15 minutes. At this time the Lubrizol 3108 andTallicin 3400 was added and mixed for another 15 minutes. A compositioncontaining the following components was prepared in accordance withExample 1, and used to protect wire rope and stranded cables:

COMPONENT SUPPLIER AMOUNT Napthenic Mineral Base Oil Lubsnap 2400/TulcoOils Inc. 67.5%  Silica Cabosil TS-720/Cabot Corp. 6.3% SyntheticCalcium Silicate Hubersorb 600/J. M. Huber 16.2%  Corp. LithiumHydroxystearate Witco Corp. 2.5% Polyisobutylene Indopol H-100/Amoco2.5% Wetting Agent** Additive 3108/Lubrizol Corp. 2.5% Tallicin3400/Pflaumer Brothers, Inc. Micronized Polyethylene S-395-N5/ShamrockInc.   2% Blue Dye Ackrochem 626/Ackron 0.5% Chemical Co. **Tallicin3400 is sold commercially as being a proprietary composition. Examplesof other suitable wetting agents comprise at least one member selectedfrom the group consisting of pine oils, tall oil, pine oil derivatives,tall oil derivatives, mixtures thereof, among others.

EXAMPLE 8

The following formula was prepared in accordance with Example 1, andapplied to a steel panel to form an outer self-supporting layer that wassubsequently covered with an external layer of wollastonite insulation:

COMPONENT SUPPLIER AMOUNT Polyalfaolefin Base Oil Durasyn 174/Amoco OilCo. 51.6% Linseed Oil commercial 30.0% Cobalt Naphthenate commercial0.1% Silica Cabosil TS-720/Cabot Corp. 4.7% Synthetic Calcium Hubersorb600/J. M. Huber Corp. 11.7% Silicate Polybutene Based IdaTac M256/Ideas,Inc. 1.5% Tackifier Dye Indigo/Tricon Color Corp. 0.4%

EXAMPLE 9

The benefit of adding polymer to an inventive composition wasdemonstrated by adding a polymer gel to a base gel formula that wasprepared in accordance with Example 1 and has the following formula:

BASE GEL COMPONENT SUPPLIER AMOUNT Polyalfaolefin Oil Durasyn 174(Amoco) 55.2 wt. % Fumed Silica Cabosil TS-720 (Cabot Corp.)  9.8 wt. %Sodium Silicate G Grade (PQ Corp.)   30 wt. % Zinc Borate Borogaro ZB(U.S. Borax)   5 wt. %

POLYMER GEL

Polyurethane polymer was added to the gel by mixing ACE 0.16381Polyurethane Clear Finish (supplied by Westlakes) with the aformentionedbase gel in a 1:15 ratio by weight respectively. The gel and polymercompositions were mixed with a spatula for approximately 15 minutes toform a homogeneous mixture. Standard 0.032 in.×3 in.×6 in. cold rollsteel panels (supplied by ACT) were coated with a 0.05 inch thick layerover a 4 inch by 3 inch area. One panel was coated with the Base GelFormula and one panel was coated with the Polymer Gel containingFormula.

In order to illustrate the effectiveness of the polymer gel formula toprotect metal surfaces from corrosion under insulation, a piece ofwollastonite mineral pipe insulation (approximately 0.25 inches×1.5inches×5 inches) was placed on each gel coated panel with the broadsurface contacting the gel. A 71 gram weight was placed on top of eachpiece of insulation and the panels were allowed to sit at ambientconditions for 48 hours. At 48 hours, the weight and insulation wasremoved and the following observations and measurements were made.

INITIAL FINAL OIL WEIGHT (g) WEIGHT (g) ABSORPTION (g) OF OF INTO GELTYPE INSULATION INSULATION INSULATION Base Gel 8.085 9.4412 1.356 g.Polymer Gel 7.562 7.673 0.111 g.

The layer of Base Gel beneath the insulation was visibly observed tohave cracks or separations in the gel due to oil loss from the gel,e.g., the oil was absorbed by the adjoining insulation. In contrast, nocracks were noted in the polymer containing gel composition. Asillustrated above, the polymer gel reduced oil loss or migration intothe insulation to less than one tenth of the loss that the Base Gelexhibited.

This Example was repeated by replacing the polyurethane polymer withepoxy resins supplied by Reichhold Chemical as EPOTUF 690 and 692. Theamount of epoxy was 20 wt. % of the total composition.

EXAMPLE 10

A substantially biodegradable formulation having the followingformulation was prepared:

COMPONENT SUPPLIER AMOUNT Polyol Ester Emkarate 1950/ICI Chemicals 67.5wt. % Fumed Silica TS-720/Cabot Corp.  5.4 wt. % Calcium silicateHubersorb H-600/J. M. Huber  3.6 wt. % Corp. Lithium Stearate WitcoCorporation 14.3 wt. % polyethylene S-395-N5/Shamrock Technologies  3.6wt. % polybutene Indopol II-300/Amoco Chemical  3.6 wt. % hydrated limeMississippi Lime Co.  2.0 wt. %

A 350 gram batch of the above composition was prepared by heating theEmkarate 1950 base oil to a temperature of 110° C., and then mixing inthe pre-mixed powdered components of the grease in a Premier Mill Series2000 Model 84 Laboratory Dispersator at N3000 rpm utilizing a 2 inchINDCO Design D dispersion blade for 15 minutes. Finally, the IndopolH-300 polybutene was added and the composition was mixed for another 15minutes. After allowing the composition to cool to room temperature, thepenetration in accordance with ASTM-D217 was measured and determined tobe 277.

Three standard 0.032 in.×3 in.×6 in. cold roll steel panels (ACTLaboratories) were rinsed with Naphtha and wiped with a Kimwipe prior toapplying 2.25 grams to the entire front panel surface (N 0.008 in.thick) with a Micrometer gate applicator. The coated panels were exposedto salt spray conditions (20% aqueous sodium chloride solution) asestablished in MIL-G-18458B for 10 days. After 10 days, the grease waswiped off and the panels were inspected for red corrosion farther than0.25 inches from the edges of the panel. Each panel had less than 7corrosion spots which exceeded 1 mm in diameter, and surface coverage bycorrosion did not exceed 5%.

EXAMPLE 11

The following Example demonstrates that certain naturally occurring baseoils are combinable with synthetic base oils. This Example alsoillustrates formation of a coating/film having a relatively firm orself-supporting outer surface and uncured material underlying the outersurface. The following compositions were prepared by in accordance withExample 7.

AMOUNT COMPONENT SUPPLIER COMPOSITION A 55-60/28-30 wt. % Linseedoil/PAO ADM/Amoco 2:1 ratio 0.75-1.0 wt. % calcium silicate-Hubersorb J.M. Huber Corp 600 2.0 wt. % amber wax-Bareco Bareco- Ultraflex Petrolite6-8 wt. % fumed silica-Cabosil 610 Cabot Corp. COMPOSITION B 55-60/28-30wt. % Linseed oil/PAO ADM/Amoco 2:1 ratio 0.75-1.0 wt. % calciumsilicate-Hubersorb J. M. Huber Corp 600 5.0 wt. % amber wax-BarecoBareco- Ultraflex Petrolite 6-8 wt. % fumed silica-Cabosil 610 CabotCorp.

These compositions were applied by using a drawndown gate onto an ACTsteel test panel. The composition formed a coating/film in about 24hours by drying under ambient conditions. The characteristics of thecoating/film were an outer self-supporting and resilient layer. Theportion of the coating/film between the outer layer and test panelremained uncured in a substantially uncharged physical state. Whenapplied to the test panel the coating/film imparted enhanced corrosionresistance to panel, in that the outer layer is water resistant andrepellent while the underlying uncured portion inhibits the ability forcorrosive materials to attack the panel.

The corrosion resistance of the coating/film was demonstrated inaccordance with ASTM Test No. B-117 (salt spray) and D22147 (humidity).Test panels coated, respectively, with compositions A and B were testedtogether at 500 hrs., 750 hrs., and 1000 as per ASTM B-117. The outerself-supporting layer remained intact, was not penetrated by corrosionmaterial, and remained flexible. The portion of the coating/film underthe outer layer remained gel-like after 1,000 hrs. of salt exposure. Norust was observed via visual detection after 1,000 hours of ASTM B-117testing.

Test panels coated, respectively, with Compositions A and B were testedat 1000 hrs as per ASTM D2247. Results similar to the previous ASTMB-117 were obtained; except that the outer layer was more flexible. Norust was observed via visual detection after 1,000 hours of ASTM D2247testing.

In addition to the corrosion resistance, panels coated with CompositionB were evaluated for temperature and pressure resistance. In test twopanels were coated with Composition B, allowed to cure for 48 hrs. underambient conditions and placed into an All American brand Model No. 25Xpressure sterilizer, manufactured by Wisconsin Aluminum Foundry Co., at240F and 2X atmospheric pressure for a period of 24 hrs. The onlyvisually detectable affect was an increased darkening of the outerself-supporting layer. The temperature and pressure resistance of apanel coated with Composition B that had undergone 750 hrs. in the ASTMB117 Salt Spray was also evaluated. Similar to the aforementionedresults, the only reportable change was a darkening of the outerself-supporting layer.

EXAMPLE 12

This Example illustrates a composition, which includes synthetic andnaturally occuring oils, that forms a self-supporting layer. Thefollowing composition was prepared by Example 7:

COMPONENT SUPPLIER AMOUNT Linseed oil ADM 50-60 wt. % polybutene IndopolH-50/Ideas Inc. 20-30 wt. % calcium silicate Hubersorb 600/Huber Corp.2-8 wt. % wax Ultraflex Amber Wax 0-4 wt. % (Bareco Petrolite) fumedsilica TS610 or TS720 5-8 wt. % (Cabot Corp.) polyethelene S-395-N5 0-4wt. % (Shamrock Tech.)

The viscosity and tackiness properties of the above composition can beimproved by adding about 1-4 wt. % lithium stearate, e.g., such as thatsupplied by Reagens of Canada. The lithium stearate can be added to thecomposition by being introduced and admixed along with the othercomponents of the composition.

EXAMPLE 13

This Example illustrates a non-migrating composition that can beemployed to reduce, if not eliminate, corrosion under insulation and canbe applied to a wet surface. The following composition was prepared byExample 7:

COMPONENT SUPPLIER AMOUNT Polybutene Indopol H-50 - Ideas Inc. 54-64 wt.% Epoxy Resin EP08YF 692 - Reichhold 15-25 wt. % Chemical Fumed Silica(Cab-o-sil) TS720 - Cabot Corp. 3-8 wt. % Calcium Silicate Hubersorb600 - Huber Corp. 4-10 wt. % Lithium Stearate Reagens - Reagen Co.Canada 4-10 wt. %

The above composition was applied to a wet metallic substrate (testpanel) without adversely impacting the adhesion to the substrate. Thecomposition was also applied to a metallic substrate while the substratewas immersed in water. The characteristics of the composition can betailored by incorporating heat-bodied linseed oil, e.g., about 5 toabout 10 wt. % of OKO-S70 supplied by ADM Corp. If desired, about 5 toabout 10 wt. % silicone resin could also be incorporated into thecomposition, e.g., the silicone supplied by GE (General Electric) ofWaterford N.Y.

EXAMPLE 14

The following Example demonstrates formation of the previously describedmineral layer as a result of a component of the grease/gel interactingwith the surface of galvanize metal substrates. The interaction wasdetected by using ESCA analysis in accordance with conventional methods.

Analytical conditions for ESCA:

Instrument Physical Electronics Model 5701 LSci X-ray sourceMonochromatic aluminum Source power 350 watts Analysis region 2 mm × 0.8mm Exit angle* 50° Electron acceptance angle ±7° Charge neutralizationelectron flood gun Charge correction C-(C,H) in C is spectra at 284.6 eV*Exit angle is defined as the angle between the sample plane and theelectron analyzer lens.

Coating were made up based on the ingredients and formulation methodsshown in Example 10. Different base oils and base oil combinations,alkali silicate types, silicate amounts, and substrates were used torepresent a cross section of possible ranges. The different base oilscomprised polyalphaolefin (polymerized 1-decene) and linseed oil. Twotypes of alkali silicates were also used, sodium and calcium silicate.The concentration of the alkali silicate was also varied from 1% to 50%wt to show the range of possible concentrations. Each set of coatingswere applied onto both cold rolled and galvanized steel panels.

Each formulation was mixed together and applied onto the given substrateat a thickness between 5 and 10 mils. The coatings were allowed to setfor at least 24 hours and then removed from the substrate. Removal wasaccomplished by first scraping off the excess coating. The residualcoating was washed with the base oil used in the formulation to absorbany of the silica or silicates. Finally the excess oil is removed bywashing with copious amounts of naphtha. Not adequately removing thesilica from the residual coating, will leave behind a precipitate in thesubsequent naphtha washing, making any surface analysis more difficultto impossible.

Formulations used for ESCA/XPA analysis Sample # 1 2 3 4 5 6 7 8 Durasyn174 49.3 44.3 49.3 44.3 87  79.2 70.4 44  wt. % (PAO) Linseed Oil 49 4449 44 0 0 0 0 wt. % Fumed Silica 0.7 0.7 0.7 0.7 12  10.8 9.6 6 wt. %Sodium silicate 1 10 0 0 0 0 20 50  wt. % Calcium sili- 0 0 1 10 1 10 00 cate wt. %

ESCA was used to analyze the surface of each of the substrates. ESCAdetects the reaction products between the metal substrate and thecoating. Every sample measured showed a mixture of silica and metalsilicate. The metal silicate is a result of the reaction between themetal cations of the surface and the alkali silicates of the coating.The silica is a result of either excess silicates from the reaction orprecipitated silica from the coating removal process. The metal silicateis indicated by a Si (2 p) binding energy (BE) in the low 102 eV range,typically between 102.1 to 102.3. The silica can be seen by Si(2 p) BEbetween 103.3 to 103.6 eV. Higher binding energies (>103.8 eV) indicateprecipitated silica due to the charging effect of the silica which hasno chemical affinity to the surface. The resulting spectra showoverlapping peaks, upon deconvolution reveal binding energies in theranges representative of metal silicate and silica.

EXAMPLE 15

The following Example demonstrates formation of the previously describedmineral layer as a result of a component of the grease/gel interactingwith the surface of lead substrates. The interaction was detected byusing ESCA analysis in accordance with conventional methods.

Coatings were made up based on the ingredients shown in table shownbelow. Different alkali silicate types and silicate amounts were used torepresent a cross section of possible ranges. Two types of alkalisilicates were also used, sodium and calcium silicate. The concentrationof the alkali silicate was also varied from 5% to 50% wt to show therange of possible concentrations. Each coatings was applied onto leadcoupons. Prior to gel application, the lead coupons cut from lead sheets(McMasters-Carr) were cleaned of its oxide and other dirt by firstrubbing with a steel wood pad. The residue was rinsed away with reagentalcohol and Kim wipes.

Each formulation was mixed together and applied onto a lead coupon at athickness between 5 and 10 mils. The coatings were allowed to set for atleast 24 hours and then removed from the substrate. Removal wasaccomplished by first scraping off the excess coating. The residualcoating was washed with the base oil used in the formulation to absorbany of the silica or silicates. Finally the excess oil is removed bywashing with copious amounts of naphtha. Not adequately removing thesilica from the residual coating, will leave behind a precipitate in thesubsequent naphtha washing, making any surface analysis more difficultto impossible.

Formulations used for ESCA/XPS analysis on lead panels Sample # 1 2 3 4Durasyn 174 89 74 89 44 wt. % Fumed Silica 6 6 6 6 wt. % Sodium 0 0 5 50silicate wt. % Calcium 5 20 0 0 silicate wt. %

ESCA was used to analyze the surface of each of the substrates. ESCAdetects the reaction products between the metal substrate and thecoating. Every sample measured showed a mixture of silica and metalsilicate. The metal silicate is a result of the reaction between themetal cations of the surface and the alkali silicates of the coating.The silica is a result of either excess silicates from the reaction orprecipitated silica from the coating removal process. The metal silicateis indicated by a Si (2 p) binding energy (BE) in the low 102 eV range,typically between 102.1 to 102.3. The silica can be seen by Si(2 p) BEbetween 103.3 to 103.6 eV. The resulting spectra show some overlappingpeaks, upon deconvolution reveal binding energies in the rangesrepresentative of metal silicate and silica. The primary binding energyfor all of these samples were in the range of 102.1 to 102.3 eV.

EXAMPLE 16

The following Example demonstrates formation of the previously describedmineral layer as a result of a component of the grease/gel interactingwith the surface of GALFAN® substrates (a commercially available alloycomprising zinc and aluminum). The interaction was detected by usingESCA analysis in accordance with conventional methods.

Coatings were made up based on the ingredients shown in table shownbelow. Different alkali silicate types and silicate amounts were used torepresent a cross section of possible ranges. Two types of alkalisilicates were also used, sodium and calcium silicate. The concentrationof the alkali silicate was also varied from 5% to 50% wt to show therange of possible concentrations. Each coatings was applied onto galfancoated steel coupons. Prior to gel application, the galfan coupon, cutfrom galfan sheets (GF90, Weirton Steel), were rinsed with reagentalcohol.

Each formulation was mixed together and applied onto a GALFAN® coupon ata thickness between 5 to 10 mils. The coatings were allowed to set forat least 24 hours and then removed from the substrate. Removal wasaccomplished by first scraping off the excess coating. The residualcoating was washed with the base oil used in the formulation to absorbany of the silica or silicates. Finally the excess oil is removed bywashing with copious amounts of naphtha. Not adequately removing thesilica from the residual coating, will leave behind a precipitate in thesubsequent naphtha washing, making any surface analysis more difficultto impossible.

Formulations used for ESCA/XPS analysis on Galfan ® panels Sample # 1 23 4 Durasyn 174 89 74 89 44 wt. % Fumed Silica 6 6 6 6 wt. % Sodium 0 05 50 silicate wt. % Calcium 5 20 0 0 silicate wt. %

ESCA was used to analyze the surface of each of the substrates, ESCAdetection of the reaction products between the metal substrate and thecoating. Every sample measured showed a mixture of silica and metalsilicate. The metal silicate is a result of the reaction between themetal cations of the surface and the alkali silicates of the coating.The silica is a result of either excess silicates from the reaction orprecipitated silica from the coating removal process. The metal silicateis indicated by a Si (2 p) binding energy (BE) in the low 102 eV range,typically between 102.1 to 102.3. The silica can be seen by Si(2 p) BEbetween 103.3 to 103.6 eV. The resulting spectra show some overlappingpeaks, upon deconvolution reveal binding energies in the rangesrepresentative of metal silicate and silica.

EXAMPLE 17

The following Example demonstrates formation of the previously describedmineral layer as a result of a component of the grease/gel interactingwith the surface of copper substrates. The interaction was detected byusing ESCA analysis in accordance with conventional methods.

Coatings were made up based on the ingredients shown in table shownbelow. Different alkali silicate types and silicate amounts were used torepresent a cross section of possible ranges. Two types of alkalisilicates were also used, sodium and calcium silicate. The concentrationof the alkali silicate was also varied from 5% to 50% wt to show therange of possible concentrations. Each coatings was applied onto coppercoupons. Prior to gel application, the copper coupons cut from coppersheets (C110, Fullerton Metals) were rinsed with reagent alcohol.

Each formulation was mixed together and applied onto a copper coupon ata thickness between 5 and 10 mils. The coatings were allowed to set forat least 24 hours and then removed from the substrate. Removal wasaccomplished by first scraping off the excess coating. The residualcoating was washed with the base oil used in the formulation to absorbany of the silica or silicates. Finally the excess oil is removed bywashing with copious amounts of naphtha. Not adequately removing thesilica from the residual coating, will leave behind a precipitate in thesubsequent naphtha washing, making any surface analysis more difficultto impossible.

Formulations used for ESCA/XPS analysis on copper Sample # 1 2 3 4Durasyn 174 89 74 89 44 wt. % Fumed Silica 6 6 6 6 wt. % Sodium 0 0 5 50silicate wt. % Calcium 5 20 0 0 silicate wt. %

ESCA was used to analyze the surface of each of the substrates, ESCAdetects the reaction products between the metal substrate and thecoating. Every sample measured showed a mixture of silica and metalsilicate. The metal silicate is a result of the reaction between themetal cations of the surface and the alkali silicates of the coating.The silica is a result of either excess silicates from the reaction orprecipitated silica from the coating removal process. The metal silicateis indicated by a Si (2p) binding energy (BE) in the low 102 eV range,typically between 102.1 and 102.3. The silica can be seen by Si(2p) BEbetween 103.3 to 103.6 eV. The resulting spectra show some overlappingpeaks, upon deconvalution reveal binding energies in the rangesrepresentative of metal silicate and silica.

EXAMPLE 18

A solvent free formulation having the following components was prepared:

COMPONENT SUPPLIER AMOUNT Polybutene H-50/AMOCO 58-63 wt. % urethaneF-34 m-100 Reichhold Chem. 14-16% silica Cab-o-sil TS 720 Cabot Corp.4-6% Ca-silicate Hubersorb 600 Huber Corp. 6-10% Li-Stearate Reagens ofCanada 4-8% linseed oil OKO-S70 ADM 4-6%

The formulation was prepared by adding the polybutene base oil into ainto 600 mL stainless steel beaker mixing container. The OKO S70 linseedoil was added and stirred into the polybutene to form a first mixture.The mixture was heated to a temperature of 150 F. by placing the mixingcontainer on a hot plate.

Using a mixing apparatus similar to one described above in Example 10,the powdered components of the formulation were admixed into the heatedbase oil (or first mixture). The powdered components were addedgradually until the admixture is relatively thick.

A second mixture was prepared by heating the Urethane to a temperatureof 150 F. thereby forming a liquid. The second mixture was introducedinto the first mixture and blended in the 600 mL stainless steel beakeruntil smooth. A vacuum was applied to the formulation to remove anyentrained air. The formulation was allowed to cool to room temperaturebefore testing or application.

The thermal stability of the formulation was tested in accordance withExample 11 above. The formulation sustained heat at 220 F. for 7 dayswith no visible adverse affects. The hydrothermal stability of theformulation was tested in accordance with Example 11 above for a period24 hrs. at 240-250 F. at a pressure of 1 atmosphere(gage). No adverseaffects were visually detected. The corrosion resistance of theformulation was tested in accordance with the B117 salt corrosionprocedures set forth above in Example 11. After 10 days exposure, a0.010 in. thickness coating of the formulation upon a steel test panelpossessed less than 5% surface area red rust.

The formulation was applied upon a steel panel and covered withwollastonite insulation in order to determine oil loss into theinsulation. The insulation was removed and inspected for oil migratingfrom the formulation into the insulation. After a period of 7 days, lessthan 15 wt. % of the oil had been absorbed by the insulation.

EXAMPLE 19

A solvent free formulation having the following components was prepared:

COMPONENT SUPPLIER AMOUNT Polybutene H-50/AMOCO 58-63 wt. % epoxy EponSU 2.5/Shell Oil 14-16% silica Cab-o-sil TS 720 Cabot Corp. 4-6%Ca-silicate Hubersorb 600 Huber Corp. 6-10% Li-Stearate Reagens ofCanada 4-8% linseed oil OKO-S70 ADM 4-6%

The formulation was prepared by adding the polybutene base oil into ainto 600 mL stainless steel beaker mixing container. The OKO S70 linseedoil was added and stirred into the polybutene to form a first mixture.The mixture was heated to a temperature of 150 F. by placing the mixingcontainer on a hot plate. Using a mixing apparatus similar to onedescribed above in Example 10, the powdered components of theformulation were admixed into the heated base oil (or first mixture).The powdered components were added gradually until the admixture isrelatively thick.

A second mixture was prepared by heating the SU2.5 epoxy to atemperature of 150 F. thereby forming a liquid. The second mixture wasintroduced into the first mixture and blended in a 600 mL stainlesssteel beaker until smooth. A vacuum was applied to the formulation toremove any entrained air. The formulation was allowed to cool to roomtemperature before testing or application.

The thermal stability of the formulation was tested in accordance withExample 11 above. The formulation sustained heat at 250 F. for 3 daysand at 300 F. for 10 days with no visible adverse affects. Thehydrothermal stability of the formulation was tested in accordance withExample 11 above for a period 24 hrs. at 240-250 F. at a pressure of 1atmosphere. No adverse affects were visually detected. The corrosionresistance of the formulation was tested in accordance with the B117salt corrosion procedures set forth above in Example 11. After 10 daysexposure, a 0.010 in. thickness coating of the formulation upon a steeltest panel possessed less than 5% surface area red rust.

For best results, the liquid components, e.g., polybutene, are added toa mixing vessel and heated to a temperature of about 150 to 160 F. Aftermixing at the elevated temperature, a vacuum is applied to removedentrained air, e.g., a vacuum of about 20 to 25 inches. The solidcomponents, e.g., fumed silica, are introduced to the bottom of theheated mixing vessel and into the liquid components, and continue toheat and mix while drawing the vacuum. Resinous components, e.g., epoxy,are added to the mixing vessel.

EXAMPLE 20

A prep-coating or primer formulation having the following formulationwas prepared:

COMPONENT SUPPLIER AMOUNT polybutene L-50 or L-14/AMOCO 96-98% silicaCab-o-sil TS 720/Cabot Corp 1-2% ca-silicate Hubersorb 600/Huber Corp1-2%

The components of this formulation were admixed in accordance with themethod described in Example 7. This formulation can be applied upon a 2inch iron pipe as a primer or pre-coating before application of a CUIinhibitor such as the formulation described in Examples 18 and 19. Theprimer functions to penetrate surface non-uniformities and scale.

EXAMPLE 21

This Example demonstrates lanolin containing gel formulations. Theseformulas can be used to reduce corrosion on wire ropes. Theseformulations can be introduced into the wire rope during manufacture orthereafter by hand or pressure application methods.

COMPONENT SUPPLIER COMPONENT Wt. % Wt. % Wt. % Wt. % Wt. % Wt. % Wt. %Wt. % Lanactex Products Lanolin USP 32.50 5.00 13.75 13.75 13.75 10.0014.50 10.50 Inc. Cabot Corporation Cabosil TS-720, Fumed 6.50 6.50 6.506.50 6.50 6.50 6.80 6.80 Silica Reagens Comiel Lithium Stearate 5.0010.00 10.50 Canada Witco Corporation SAC1760, Calcium 5.00 5.00Sulfonate Shamrock S-395-N5 Polyethylene 27.50 5.00 Technologies ShellChemical EPON Resin SU-2.5, 13.75 13.75 13.75 7.50 14.50 8.00 CompanyEpoxy Resin Amoco Chemical Durasyn 174 PAO, 61.00 61.00 61.00 61.0061.00 61.00 64.20 64.20 Company Polyalfaolefin Oil

These formulations were prepared by heating the polyalphaolefin oil to atemperature of 150 F. in a 600 mL stainless steel beaker mixingcontainer. While maintaining the temperature at 150 F., the lanolincomponent was mixed into the oil with a glass stirring rod therebyforming a mixture. The remaining components were blended together andintroduced into the mixture.

Each of these formulations was tested for corrosion resistance inaccordance with Federal Test Standard 791c, Method 4001.3 (20% saltspray). The formulation was applied with an adjustible gate applicatoronto standard cold roll steel test panels (ACT Laboratories) atapproximately 0.008 inches thick and placed into a testing chamber. Eachof the formulations survived 1 4days salt spray without any visiblesigns of rust.

EXAMPLE 22

This Example demonstrates using sodium silicate powders having arelatively small particle size in a wide range of formulations. TheseExamples were prepared in accordance with the method described inExample 21. These formulations were tested in accordance with themethods described above in Example 21 and survived 14 days in salt spraywithout any visible signs of rust.

COMPONENT SUPPLIER COMPONENT Wt. % Wt. % Wt. % Wt. % Wt. % Wt. % Wt. %Wt. % Lanactex Products Lanolin USP 5.00 13.75 10.00 10.00 10.00 14.70Inc. Cabot Corporation Cabosil TS-720, Fumed 6.50 6.50 6.50 6.50 6.506.50 6.50 6.60 Silica Reagens Comiel Lithium Stearate 10.00 10.00 7.504.90 Canada Witco Corporation SAC1760, Calcium 2.50 2.50 7.40 SulfonateShamrock S-395-N5 Polyethylene 27.50 27.50 5.00 2.50 Technologies FQCorporation Sodium Silicate (less 32.50 5.00 5.00 5.00 2.50 2.50 2.50than 200 mesh) Shell Chemical EPON Resin SU-2.5, 13.75 7.50 7.50 5.007.40 Company Epoxy Resin Amoco Chemical Durasyn 174 PAO, 61.00 61.0061.00 61.00 61.00 61.00 61.00 54.00 Company Polyalfaolefin Oil

EXAMPLE 23

A formulation having the following formulation was prepared inaccordance with Example 11.

COMPONENT SUPPLIER AMOUNT Polybutene H-50 AMOCO 58-63 wt. % Epoxy ResinEP0tuf 692 - Reichhold 15-20 wt. % Chemical Linseed Oil OKO S70-ADM 2-5wt. % Fumed Silica (Cab-o-sil) TS720 - Cabot Corp. 4-6 wt. % SodiumSilicate >200 mesh PQ Corp 8-10 wt. % Lithium Stearate Reagens - ReagenCo. Canada 4-7 wt. %

EXAMPLE 24

The corrosion resistance or ability of the inventive grease/geldescribed in Examples 13 and 23 to inhibit rust formation was determinedin accordance with “Measurement of Corrosion Under Insulation andEffectiveness of Protective Coatings” by Dharma Abayaratha et al., March1997, NACE International; the disclosure of which is hereby incorporatedby reference. This testing method determines the rate of corrosion as afunction of electrical resistance.

The results of this determination are better understood by reference toFIG. 1. Referring now to FIG. 1, FIG. 1 is a graphical representation ofthe corrosion rate of unprotected steel pipe (Plot A), a steel pipecoated with the formulation of Example 23 (Plot B) and a steel pipecoated with the formulation of Example 13 (Plot C). A layer of pearliteinsulation was placed over all of the test pipes. Each of the pipes wasexposed to an environment that cycled between salt water at 150 F. todrying at 230 F. As illustrated by FIG. 1, Plot A, an unprotected pipecorrodes rapidly under insulation whereas the inventive grease/gelreduces, if not eliminates, corrosion under insulation.

EXAMPLE 25

This Example illustrates one method for spraying an inventive grease-gelcomposition upon a metal surface. The following two compositions wereprepared in accordance with Example 19, and were sprayed individuallyupon a flat steel surface:

Component Component Component Component Name Manufacturer Percentpolybutene Indopol H-50 Amoco Chemical Co. 61%  linseed oil OKO-S-70 ADMCorp. 5% epoxy resin Epon SU-2.5 Shell Chemical Co. 15%  silica CabosilTS-720 Cabot Corp. 5% ca-silicate Hubersorb 600 J. M. Huber Corp. 8%li-stearate Lithium Stearate Reagens Canada LTD 6% polybutene IndopolH-50 Amoco Chemical Co. 61%  linseed oil OKO-S-70 ADM Corp. 5% urethaneSpenkel F34-M-100 Reichhold Chemical 15%  resin Co. silica CabosilTS-720 Cabot Corp. 5% ca-silicate Hubersorb 600 J. M. Huber Corp. 8%li-stearate Lithium Stearate Reagens Canada LTD 6%

These two compositions were diluted with a combination of mineralspirits and reagent alcohol at a ratio of 5:1 to 7:1 parts. The combineddiluent was present at 12 to 13 wt. % of the mixture to be sprayed. Thecompositions were sprayed by using a Graco 10:1 air pump sprayer, Model#207-352, Series I97 F, or a Graco 5:1 air pump sprayer, Model #205-997,Series E4G. The Air Pressure setting for the pumps was 50 PSI; InletPressure to pump-50 PSI; Fluid Flow-100 PSI. The average thickness forCompositions I and II was 0.050 in., 4.5 sq. ft. coverage per lb. ofmaterial, and the application time to cover 1 sq. yd. was 6 minutes.

If desired, a coating can be applied upon a rough or corroded surface(with no loose debris) before spraying the previously describedcompositions. A suitable pre-treatment or prep-coat comprises theformulas shown below. The prep-coat works well on heavily rustedsurfaces, soaking into the rusted areas and allowing for less base oilin the overlying coatings to be drawn out. The following two prep-coatcompositions were prepared by adding the fumed silica and calciumsilicate to the polybutene oil or pre-blended polybutene oil and linseedoil and mixed at 2000 rpm for 15 minutes utilizing a Design D dispersionblade (INDCO) mounted on a Premier Mill Series 2000 model 84 laboratorydispersator.

COMPONENT NAME SUPPLIER AMOUNT Comp I  Prepcoat polybutene oil L-50Ideas Inc. 98 wt. % fumed silica TS 720 Cabot Corp. 1% Ca-silicateHubersorb Huber Corp. 1% Comp II Prepcoat polybutene oil L-50 Ideas Inc.49 wt. % linseed oil Alinco Y ADM 49%  fumed silica TS 720 Cabot Corp.1% Ca-silicate Hubersorb Huber Corp. 1%

EXAMPLE 26

This Example demonstrates the ability of the gel to form a non-tackyexterior layer or film. This exterior layer imparts improve waterrepellency to an applied gel. Such resistance is desirable whenemploying the gel in outdoor environments such as piping andinfrastructure, e.g., insulated pipes in a chemical processing facility.

The gel composition of Example 19 was applied as a {fraction (1/16+L )}inch film onto a steel pipe. The applied gel was heated in an oven byincreasing to a temperature of about 120 to 150 C. The color of theapplied gel change from white to tan within 48 hours from the heattreatment. The surface tackiness of the gel was reduced as a result of arelatively firm exterior film or layer formed upon the gel surface. Theportion of the gel underlying the exterior film remained tacky andfluid.

EXAMPLE 27

This Example illustrates an inventive gel that employs an EPL base oilcomprising soy bean oil. The compositions were prepared by heating thesoy salad oil to 150 F. and adding the lanolin while mixing in a mixingbowl until the lanolin was dissolved and completely dispersed. Next thefumed silica was added and mixed by hand until all the powder was wettedout and then mixed at 2500-3,000 RPM in a mixing bowl for 15minutes. Thelithium stearate and polyethylene were added and mixed for 5 minutes,and followed by the epoxy resin with subsequent mixing for 10 minutes.At this time the batch was mixed at 2,500-3,000 RPM for an additional 15minutes. Calcium sulfonate was added to the batch and mixed at2,500-3,000 RPM for 10 minutes.

WT % COMPONENT DESCRIPTION SUPPLIER A B Soybean oil Soy Salad Oil (ADMCorp.) 53.5% 57.8% Lanolin USP (Lanaetex Corp.) 15.0% 16.2% fumed silicaCabosil TS-720 (Cabot Corp.) 6.5% 7.0% Lithium commercial grade (ReagensCanada) 5.0% 5.5% Stearate polyethylene S-395-N5 (Shamrock 2.5% 2.7%Technol.) >200 mesh Sodium Silicate (PQ Corp.) 2.5% 2.7% epoxy resinEpon SU-2.5 (Shell Chemical) 7.5% 8.1% ca-sulfonate Lockguard B8260(Lockhart) 7.5%

Formulations A and B were repeated except that the sodium silicate wasreplaced with calcium silicate (Hubersorb 600 supplied by J. M. Huber).These formulations are useful as a biodegradable lubricant; especiallyfor marine applications.

EXAMPLE 28

The following compositions are prepared in accordance with the method ofExample 27:

COMPONENT DESCRIPTION SUPPLIER WT % FORMULA 1 Soybean Oil Soybean Oil(Soy-Co LLC) 60.00% Sodium Silicate Baghouse Fines (PQ Corp.)  5.00%Fumed silica Cabosil TS-720 (Cabot Corp.) 10.00% Lithium StearateCommercial (Reagens Canada) 10.00% grade Oil Modified Urethane Spenkel(Reichhold) 15.00% F-34-M-100 FORMULA 2 Soybean Oil Soybean Oil (Soy-CoLLC) 60.00% Sodium Silicate G Grade (PQ Corp.)  5.00% Fumed silicaCabosil TS-720 (Cabot Corp.) 10.00% Lithium Stearate Commercial (ReagensCanada) 10.00% grade Oil Modified Urethane Spenkel (Reichhold) 15.00%F-34-M-100 FORMULA 3 Soybean Oil Soybean Oil (Soy-Co LLC) 49.50% SodiumSilicate Baghouse Fines (PQ Corp.)  5.00% Fumed silica Cabosil TS-720(Cabot Corp.) 10.00% Lithium Stearate Commercial (Reagens Canada) 10.00%grade Oil Modified Urethane Spenkel (Reichhold) 15.00% F-34-M-100Lanolin Lanolin, USP (Lanaetex Corp.) 10.00% a-Tocopherol AcetateVitamin E (BASF) 0.50 Acetate FORMULA 4 Soybean Oil Soybean Oil (Soy-CoLLC) 49.50% Sodium Silicate G Grade (PQ Corp.)  5.00% Fumed silicaCabosil TS-720 (Cabot Corp.) 10.00% Lithium Stearate Commercial (ReagensCanada) 10.00% grade Oil Modified Urethane Spenkel (Reichhold) 15.00%F-34-M-100 Lanolin Lanolin, USP (Lanaetex Corp.) 10.00% a-TocopherolAcetate Vitamin E (BASF)  0.50% Acetate FORMULA 5 Soybean Oil SoybeanOil (Soy-Co LLC) 60.00% Calcium Silicate Hubersorb 600 (D&F Distrib.) 5.00% Fumed silica Cabosil TS-720 (Cabot Corp.) 10.00% Lithium StearateCommercial (Reagens Canada) 10.00% grade Oil Modified Urethane Spenkel(Reichhold) 15.00% F-34-M-100 FORMULA 6 Soybean Oil Soybean Oil (Soy-CoLLC) 49.50% Calcium Silicate Hubersorb 600 (D&F Distrib.)  5.00% Fumedsilica Cabosil TS-720 (Cabot Corp.) 10.00% Lithium Stearate Commercial(Reagens Canada) 10.00% grade Oil Modified Urethane Spenkel (Reichhold)15.00% F-34-M-100 Lanolin Lanolin, USP (Lanaetex Corp.) 10.00%a-Tocopherol Acetate Vitamin E (BASF)  0.50% Acetate FORMULA 7 SoybeanOil Soybean Oil (Soy-Co LLC)   85% Fumed Silica Cabosil TS-720 (D&FDistrib.)  2.0% Calcium silicate Hubersorb 600 (D&F Distrib.)  3.0%D'limonene citrus product commodity   10%

If desired, the soybean base oil can be replaced with a blend of soybeanoil with at least one synthetic oil, e.g. polyalphaolefin, polybutene,among others.

EXAMPLE 29

The formulation listed below was produced by adding powdered materialsto the PAO base oil, i.e., polymerized 1-decene. The PAO oil was pouredinto a 1 quart stainless steel bowl. The powdered materials were thenadded to the PAO and mixed by hand.

NAME AMOUNT WT. COMPONENT SUPPLIER % BY Durasyn 174 PAO base oil Ideas,Inc. 59.0% Cabosil TS-720 Silica Cabot Corp. 10.0% G sodium silicate PQCorp. 25.0% Borogard ZB zinc borate U.S. Borax 5.0% Indigo Blue dyeTricon Colors Inc. 1.0%

This composition, when applied to a standard ACT electrogalvanized steeltest panel (E60 EZG 60G 2 side 03×06×030) to a thickness of {fraction(1/16+L )} inch, protects from red corrosion for a minimum of 1000 hoursin accordance with ASTM B117 salt spray exposure. When the compositionwas removed from the panel after a minimum of 24 hours by carefullyscraping off the excess and then washing with naphtha, an average of 192hours of ASTM B117 salt spray exposure was obtained prior to theappearance of red corrosion products compared to 120 hours for untreatedcontrol samples.

EXAMPLE 30

The formulation provided below was prepared by the method described inExample 27:

COMPONENT DESCRIPTION SUPPLIER WT % Polyalphaolefin Oil Durasyn 174 PAO(Ideas, Inc.) 53.5% Lanolin USP (Lanaetex Corp.) 15.0% fumed silicaCabosil TS-720 (Cabot Corp.) 6.5% Lithium Stearate commercial grade(Reagens Canada) 5.0% polyethylene S-395-N5 (Shamrock 2.5%Technol.) >200 mesh Sodium Silicate (PQ Corp.) 2.5% epoxy resin EponSU-2.5 (Shell Chemical) 7.5% ca-sulfonate Lockguard B8260 (Lockhart)7.5%

The above composition was applied to a standard steel ACT 3″X6″X0.032″test panel in a uniform thickness of 0.008 in. thick and exposed toASTM-B117 salt spray for 1728 hours (72 days). After the exposure periodthe gel composition was removed and the underlying substrate steel haddeveloped corrosion on only 1-2 % of its surface.

EXAMPLE 31

The formulation provided below was prepared by the method described inExample 27:

COMPONENT DESCRIPTION SUPPLIER WT % Polybutene Oil Indopol H-25 (Ideas,Inc.) 45.0% Lanolin USP (Lanaetex Corp.) 10.0% fumed silica CabosilTS-720 (Cabot Corp.) 5.0% Lithium Stearate commercial grade (ReagensCanada) 5.0% polyethylene S-395-N5 (Shamrock 5.0% Technol.) >200 meshSodium Silicate (PQ Corp.) 20.0% epoxy resin Epon SU-2.5 (ShellChemical) 5.0% ca-sulfonate SACI 760 (Witco Corp.) 5.0%

The above composition has a penetration value of 291(ASTM-D217), and anNLGI2 grade grease consistency.

EXAMPLE 32

The inventive compositions described in Examples 25 and 30 were preparedin accordance with the method described in Examples 19 and 27respectively. The composition was tested in accordance with ASTME-729-88a. A 96 hour static acute toxicity screening test with saltwatermysid (Mysidopsis bahia) was preformed. All of the mysid appeared normalafter 96 hour exposure to concentrations of the composition ranging from1 mg/L to 100 mg/L. This result illustrates the inventive composition isnon-toxic.

EXAMPLE 33

The following Example illustrates compositions that form aself-supporting outer layer or skin. Additives were incorporated intothe gel of Example 19 by hand mixing. If desired, mechanical mixers arealso a means of dispersing the additives throughout the grease, e.g., toincorporate the additives in the initial mixing process.

The following samples were formulated to evaluate depth of cure,reactivity to differing light sources, and toughness of film. Thecomponents of the samples are given in parts.

Sample Gel CN111 Darocure 1173 Irgacure 819 TiO2 A 100 20 2 B 100 20 3 C100 20 3 1 D 100 20 2 1 E 100 20 2 F 100 20 3 G 100 20 3 1 H 100 20 2 1

CN111 comprises an epoxidized soybean oil (supplied by Sartomer).Darocure 1173 comprises a acetophenoc based photoinitiator (supplied byCiba). Irgacure 819 comprises a phosphene oxide photoinitiator (suppliedby Ciba), TiO2 titanium dioxide was employed as a pigment to control thethickness of the self-supporting layer.

The Samples described above where then applied onto an ACT steel testpanel and exposed to various sources of UV light. The thickness of theresultant self-supporting layer are described below.

Sample Sunlight exposure UV(1.6 J/cm2) UV(.8 J/cm2) A skin skin skin Bskin skin skin C skin slight skin slight skin D slight skin slight skinslight skin E skin skin skin F skin skin skin G skin skin skin H skinskin skin

The above samples were also exposed to conventional fluorescent lightingwithout any visually detected affect. The heat tolerance and corrosionresistance (ASTM B-117) of the above samples was tested.

Heat Tolerance was measured by oven heat aging at 350 F. ACT SteelPanels were coated with each of the above samples having a thicknessstarting at 0.005 in. at one end, tapering out to 0.030 in. at the otherend of the panel. The coated panels were placed outside for UV (8 hour)cure, set inside overnite, and then placed into the oven at 350 F. Thecoated panels remained in the oven for over 500 hours without crackingor excessive chalking.

The heat tolerance test was repeated except that the samples wereapplied onto on a 3 in. dia. steel pipe. The coated pipes were exposedto UV light as described above and placed into an oven at 350 F. Thecoated pipes remained in the oven for over 350 hours without cracking orexcessive chalking.

Corrosion Resistance was measured in accordance with ASTM-B117 (saltfog). ACT Steel Panels were coated with each of the above samples havinga thickness starting at 0.005 in. at one end, tapering out to 0.030 in.at the other end of the panel. The coated panels were placed outside forUV (8 hour) cure, set inside overnite, and then placed into a B-117 saltchamber. The coated panels remained in the salt chamber for over 500hours with corrosion failure.

EXAMPLE 34

The following formulations were prepared in accordance with Example 19.These formulations are especially suitable for use in lubricating andpreventing corrosion in roller chain and links. In such an applicationthese formulations are preferably ultra-sonically or vacuum infiltratedinto the chain. The rate of application can be enhanced by heating theformula.

TRADE NAME/SUPPLIER COMPONENT AMOUNT FORMULA 1 Alinco Y-ADM linseed oil32-35 wt % L-50-Ideas Inc. polybutene oil 32-35% Hubersorb 600-HuberCa-silicate 1-2% TS 720 Cabosil-Cabot silica 1-2% Ultraflex-Bareco amberwax 6% 12 hydroxy-Witco Li-stearate 2% Durad 310 M-FMC TriphenylPhosphate 1% RI-CA-J. T. Vanderbilt calcium sulfonate 22-25% FORMULA 2Alinco Y-ADM linseed oil 31-33 wt % L-50-Ideas Inc. polybutene oil31-33% Hubersorb 600-Huber Ca-silicate 5% TS 720 Cabosil-Cabot silica1-2% Ultraflex-Bareco amber wax 4-5% 12 hydroxy-Witco Li-stearate 2%Durad 310 M-FMC Triphenyl Phoshate 1% RI-CA-J. T. Vanderbilt calciumsulfonate 20-22%

EXAMPLE 35

This Example demonstrates the ability of the inventive grease/gel toreduce stress crack corrosion. These tests were conducted on stressedU-bend specimens made from AISI 304 stainless steel. Duplicate specimenswere exposed in the untreated condition and also following applicationof the composition described in Example 19. Both untreated specimensexhibited evidence of localized corrosion and stress corrosion cracking(SCC). By comparison the specimens treated with the inventivecomposition were free of localized corrosion and cracking in the sametest exposure.

Four U-bend specimens were made from AISI 304 stainless steel. Thesespecimens were given a senitization heat treatment at 1200 F. (650 C.)for 8 hours prior to stressing and exposure. Two specimens were leftuntreated and two were treated with the inventive composition. Sixdefected areas were made in the treated layer and cotton wicks wereplaced in these regions to retain moisture.

The U-bend specimens were placed over a stainless steel pipe section andstressed. The exposure sequence was substantially the same as thatdescribed in ASTM C692. This consisted of applying foam glass thermalinsulation around the U-bend specimens that conformed to their shape.Once assembled, a 1500 C1″ solution (2.473 g/L NaCl) was continuouslyintroduced to the tension surface of the specimens through holes in theinsulation. The flow rate was regulated to achieve partial wet/dryconditions on the test specimen. The pipe section was internally heatedusing a cartridge heater and a heat transfer fluid and test temperaturecontrolled at 160 F. The test was run for a period of 100 hours followedby examination of the test specimens.

Both untreated U-bend specimens showed evidence of SCC originating fromregions of localized corrosion on the tension surface. The cracks areshown in FIG. 1 which indicate the branched nature of the cracking. Bycomparison, as indicated in FIG. 2, neither of the two U-bend specimenstreated with EDC 2000 showed any evidence of localized corrosion or SCC.

EXAMPLE 36

These tests were conducted to examine the influence of gel surfacetreatments on the susceptibility of AISI 304 stainless steel coupons.The tests revealed improvement in pitting resistance for samplesfollowing surface treatment with the inventive composition of Example19.

Four corrosion coupons of AISI 304 stainless steel were used in thisexample. One specimen was tested without surface treatment. Twoadditional specimens were tested following hand application of theinventive composition one of which contained a defected regionconsisting of a “X” across the face of the specimen.

The test specimens were exposed according to ASTM G48 Method A (FerricChloride Pitting Test). These tests consisted of exposures to a ferricchloride solution (about 6 percent by weight) at room temperature for aperiod of 72 hours.

The results of the corrosion tests are given in the following Table.They indicate the order of corrosion performance in terms of maximum pitpenetration rate (from best to worst) was as follows: (1) inventive gelof Example 19, (2) gel treatment with “X” defects, (3) No treatment.There were minimal visible signs of localized attack on the coupon withthe full EDC 2000 treatment. However, all other conditions showedsignificant areas of pitting. Attack on the coupon with the fulltreatment and the “X” defect was mainly limited to the region of thedefect and on the ends of the coupon.

TABLE Results of ASTM G48 Pitting Tests Max. Pit Depth Pit PenetrationRate Sample (mils) (mpy) Comments Control 5.51 670 Largest pits onedges. Smaller pits on surface. Treated with 4.72 575 Pits in area of“X” Gel and “X” and on edges Gel Treated 0.24 28.7 Very limited pittingon edges only.

ASTM G-48, 304 SS Coupons Exposure to Ferric Chloride, 72 Hours, AmbientTemperature INITIAL WEIGHT WEIGHT AFTER SCALE WEIGHT SURFACE CORR.WEIGHT AFTER TEST TEST CLEANED WEIGHT LOSS AREA TIME DENSITY RATE SAMPLE(g) (g) (g) (g) (g)* (sq. in) (hrs) (g/cc) (mpy) (Bare Steel) 28.649627.7753 27.7279 −0.8743 0.9217 4.74 72.0 7.80 184.856 (EDC 2000 28.761628.6709 28.6663 −0.0907 0.0953 4.75 72.0 7.80 19.093 with X) (EDC 200028.6335 28.6267 28.6239 −0.0068 0.0096 4.72 72.0 7.80 1.934 Full Co)

EXAMPLE 37

This Example demonstrates preparing an aerosol spray of the inventivegrease or gel. The compositions of Examples 18, 19 and 25 (Comp. 2-PrepCoat) were each diluted with 30 wt. % of naphtha (mineral spirits). Thepropellants comprises A-70 (isobutene), dimethylether, andtetrafluoroethane (HFC-134a). The spray propellants were kept at aconstant 30 mls/container while three different concentrations of eachcomposition was were used, 150 gms, 130 gms, and 120 gms in thecontainer. All of the compositions were dispensed by the propellant.HFC-134a was the most effective at dispensing a spray, whereas DME andA-70 dispensed a stream of the compositions. Those skilled in this artunderstand that the spray pattern can be tailored by selecting apreferred nozzle.

EXAMPLE 38

The following composition was prepared in accordance with Example 19.

AMOUNT COMPOSITION SUPPLIER 55% Soy Salad Oil ADM Corp. 18% Indopol L-50Polybutene Amoco 20% Lockgard 9245 Calcium Sulfonate Lockhart ChemicalCo.  1% Durad 150 Phosphate Ester FMC Corp.  2% Cabosil TS-720 FumedSilica Cabot Corp.  4% Idatac C-357 Tackifier Ideas, Inc.

The composition can be diluted with about 30 to 40 wt. % mineral spiritsor naphtha. If desired, the diluted composition can be combined with apropellant in order to dispense the composition as an aerosol. Thecomposition, either as an aerosol or in bulk, is useful as a penetratingliquid for loosing corroded articles such as fasteners, bolts, nuts,among other articles subject to crevice corrosion.

EXAMPLE 39

The formulations in the following Table are based upon a soy oil baseoil and were prepared in accordance with the method of Example 19. Thesecond Table illustrated the penetration and corrosion resistance (asdetermined by ASTM B-117) for the formulations in the first Table.

Soy Reagens Shamrock Formulation ADM Soy Soyco L.L.C. Laneate x CabotCorp. T.O.W. Ind. J. M. Huber Lithium Polyethylene Number Salad OilSoybean Oil Lanolin USP Cabosil TS-720 Genie Gel Hubersorb 600 StearateS-395-N5  1 53.80 15.10 6.50 5.00 2.50  2 57.80 16.20 7.00 5.40 2.70  360.00 10.00 5.00 10.00  4 49.50 10.00 10.00 5.00 10.00  5 50.00 10.0010.00 5.00 10.00  6 50.00 10.00 10.00 5.00 10.00  7 60.00 10.00 5.0010.00 5.00  8 87.50 7.50 5.00  9 77.50 7.50 15.00 10 67.50 7.50 25.00 1175.00 10.00 15.00 12 70.00 10.00 15.00 13 65.00 10.00 10.00 10.00 147.50 25.00 15 59.30 35.70 16 83.00 10.00 17 69.20 20.80 18 76.90 9.104.10 19 76.90 4.10 20 54.50 7.00 9.40 4.70 9.40 21 54.50 7.00 9.40 4.709.40 7.50 22 54.50 7.10 9.40 4.70 9.40 7.50 23 54.20 9.30 4.70 9.30 7.5024 61.50 15.00 9.40 4.70 9.40 25 59.50 10.20 5.10 10.20 26 59.50 10.205.10 10.20 27 57.00 9.50 4.75 9.50 4.75 28 64.10 7.10 23.75 29 56.3033.90 30 55.00 10.00 5.00 10.00 31 50.00 10.00 5.00 10.00 32 55.00 10.005.00 10.00 33 50.00 10.00 5.00 10.00 Soy Lockhart Lockhart PQ Corp.Shell Lockhart Reickhold Roche Formulation Chemical Lock- Chemical Lock-Witco Baghouse Epon Chemical Spenkel Vitamin E Number guard B826D guardB9245 SAC1760 Fines SU 2.5 Tekcor 700 F-34-M100 Acetate  1 7.00 2.507.50  2 2.70 8.10  3 15.00  4 15.00 0.50  5  6  7 10.00  8  9 10 11 125.00 13 5.00 14 15 5.00 16 7.00 17 5.80 18 5.80 19 5.80 20 7.50 7.50 217.50 22 7.50 23 7.50 7.50 24 25 15.00 26 15.00 27 9.50 28 29 4.75 3015.00 31 15.00 32 15.00 33 15.00 Soy Cntr Envir. Tech. Hercules FloridaFormulation Reickhold Polystyrene in Witco Lithium 12 Lubrizol Ester GumAmoco Chemical Number Aroplaz 12722 methyl soyate Hydroxy StearateLubrizol 31D8 BD-SP Indolpol H-300 d-Limonene  1  2  3  4  5 15.00  615.00  7  8  9 10 11 12 13 14 67.50 15 16 17 4.20 18 4.10 19 4.10 9.1020 21 22 23 24 25 26 27 5.00 28 5.00 29 5.00 30 5.00 31 10.00 32 5.00 3310.00

PENETRATION AND SALT SPRAY TEST RESULTS FOR SOY BASED GREASE FORMUATIONSSoy Average Formulation Penetration Pass/Fail (5% Red) AVG % Red Number(mm) 10 Days 15 Days 20 Days 25 Days  1 346 Pass Fail  2 315 BorderlineFail  3 243 Fail  4 235 Fail  5 212 Fail  6 225 Fail  7 218 Pass Fail  8346 Fail  9 308 Pass Fail 10 287 Fail 11 260 Pass Pass Fail 12 229 PassPass Fail 13 258 Pass Fail 14 N/A N/A N/A N/A 15 148 Pass Fail 16 384Fail 17 186 Pass Pass Fail 18 190 Pass Fail 19 N/A Fail 20 248 37.4 21222 15.2 22 245 31.8 23 237 52.4 24 236 66 25 255 9.7 26 214 82 27 N/AN/A 28 N/A N/A 29 N/A N/A 30 229 34.7 31 235 31.6 32 205 26.9 33 18519.8

EXAMPLE 40

The formulations described in Examples 19, 23 and 25 are repeated withthe exception that the base oil comprises soy oil. These formulationscan also include at least one of antioxidants and antimicrobial agents.These formulations can be employed upon terminal posts of conventionallead based batteries for reducing corrosion.

EXAMPLE 41

The following Tables illustrate UV curable compositions. Thecompositions amounts are given in grams. Best results are obtained byusing samples 8, 18, 19 and 23-32. These compositions can be sprayedupon a surface, e.g., metallic surface, exposed to a source of UVradiation including the sun. The cured coating can be painted or furthercoated.

SAMPLE NO. 01 02 03 04 05 06 07 08 RESIN/RUBBER LUCANT 2000 ethylenealpha olefin Mitsui Chemical 35 30 15 20 LUCANT 600 ethylene alphaolefin Mitsui Chemical RICON 131 5MA maleinized poybutadiene RiconResins 20 TRILENE 65/ 1:1 ethylene propylene Amoco 30 DURASYNcopolymer/poly alpha (durasyn) olefin blend RICON 100 polybutadien RiconResins RICON 184 polybutadien Ricon Resins RICON 134 polybutadien RiconResins NIPOL 1312 butadien acrylontrile Zeon Chemical copoymer TRILENE65 ethylene propylene Uniroyal copolymer KRATON 1203 ethylene butyleneShell polymer KRATON 207 ethylene butylene Shell polymer VITON A-100flouroelastomer Dupont Dow CURABLES CN 111 epoxidized soy bean oilSartomer 25 29 33 39 39 29 29 78 acrylate CL 1039 urethane monoacrylateUCB Radcure 10 OILS/PLASTICIZERS DURASYN/P104 3:2 poly alpha olefin/Arizona Chemical 15 phenolic resin blend (P104) P 550 polyesterglutarate C. P. Hall 25 44 25 10 20 15 SF96-350 silicone fluid GESilicones 20 PHOTOINITIATORS IRGACURE 819 trimethylbenzoyl- Cibaphenylphosphineoxide DAROCURE 1173 hydroxymethylphenyl- Ciba 3 4 4 4 5 44 8 propanone IRGACURE 184 hydroxycyclohexyl Ciba phenylketone IRGACURE500 1:1 hydroxycyclohexyl Ciba phenylketone/ benzophenone blendADDITIVES LICA 44 neopentyl[diallyl]oxy, Kenrich Petro-tri(N-ethylenediamino) chemical ethylzirconate TEXOPHOR anionicsurfactant Henkel 1 1 2 2 2 2 2 2 SPECIAL IRGACOR 153 succinic acidamine Ciba salt TINUVIN 292 hindered amine Ciba ANTIOXIDANT IRGANOX 1010hindered phenolic Ciba 1 1 1 1 1 1 1 1 CORROSION H-600 calcium silicateHuber 8 8 8 10 10 10 12 10 CONTROL LITHIUM lithium stearate Reagens 6 44 4 4 4 STEARATE BN ZPG boron nitride ZYP Coatings 6 PIGMENT RUTILE R900TiO₂ Dupont 1 1 1 1 1 1 1 VISCOSITY GILSONITE hydrocarbon resin Lexco 56 0 0 4 4 4 CONTROL/MISC. PKHP 200 phenoxy resin Phenoxy Special- 2 istsFILLERS NYAD G wallastonite Nyco TS 610 treated fumed silica Cabot 0 6 50 1 4 0 6 BARAGEL 10 bentonite clay Elementis F30D micropspheres Pierce& Stevens TOTAL 100 116 104 101 105 109 107 113 SAMPLE NO. 09 10 11 1213 14 15 16 RESIN/RUBBER LUCANT 2000 ethylene alpha olefin MitsuiChemical 30 20 20 LUCANT 600 ethylene alpha olefin Mitsui Chemical 30 1010 RICON 131 5MA maleinized poybutadiene Ricon Resins 30 TRILENE 65/ 1:1ethylene propylene Amoco DURASYN copolymer/poly alpha (durasyn) olefinblend RICON 100 polybutadien Ricon Resins 30 20 20 RICON 184polybutadien Ricon Resins RICON 134 polybutadien Ricon Resins NIPOL 1312butadien acrylontrile Zeon Chemical copoymer TRILENE 65 ethylenepropylene Uniroyal copolymer KRATON 1203 ethylene butylene Shell polymerKRATON 207 ethylene butylene Shell polymer VITON A-100 flouroelastomerDupont Dow CURABLES CN 111 epoxidized soy bean oil Sartomer 29.5 29.529.5 29.5 29.5 29.5 29.5 29.5 acrylate CL 1039 urethane monoacylate UCBRadcure 10 OIL/PLASTICIZERS DURASYN/P104 3:2 poly alpha olefin/ ArizonaChemical phenolic resin blend (P104) P 550 polyester glutarate C. P.Hall 20 20 20 20 20 20 20 20 SF96-350 silicone fluid GE SiliconesPHOTOINITIATORS IRGACURE 819 trimethylbenzoyl- Ciba phenylphosphineoxideDAROCURE 1173 hydroxymethylphenyl- Ciba 4 4 4 4 4 4 4 4 propanoneIRGACURE 184 hydroxycyclohexyl- Ciba IRGACURE 500 1:1 hydroxycyclohexyl-Ciba phenylketone/ benzophenone blend ADDITIVES LICA 44neopentyl-[diallyl]oxy, Kenrich Petro- 0.1 tri(N-ethylenediamino)chemical ethylzirconate TEXOPHOR anionic surfactant Henkel 2 2 2 2 2 2 22 SPECIAL IRGADOR 153 succinic acid amine Ciba salt TINUVIN 292 hinderedamine Ciba ANTIOXIDANT IRGANOX 1010 hindered phenolic Ciba 1 1 1 1 1 1 11 CORROSION H-600 calcium silicate Huber 10 10 10 10 10 10 10 10 CONTROLLITHIUM lithium stearate Reagens 4 4 4 4 4 4 5 5 STEARATE BN ZPG boronnitride ZYP Coatings PIGMENT RUTILE R900 TiO₂ Dupont 0.5 0.5 0.5 0.5 0.50.5 0.5 0.5 VISCOSITY GILSONITE hydrocarbon resin Lexco 4 4 4 4 4 4 4 4CONTROL/MISC. PKHP 200 phenoxy resin Phenoxy Special- ists FILLERS NYADG wallastonite Nyco TS 610 treated fumed silica Cabot 0 2 0 2 0 4 2 2BARAGEL 10 bentonite clay Elementis F30D micropheres Pierce & StevensTOTAL 105 107 105 107 106 109 108 108.1 SAMPLE NO. 17 18 19 20 21 22 2324 RESIN/RUBBER LUCANT 2000 ethylene alpha olefin Mitsui Chemical LUCANT600 ethylene alpha olefin Mitsui Chemical RICON 131 5MA maleinizedpoybutadiene Ricon Resins TRILENE 65/ 1:1 ethylene propylene AmocoDURASYN copolymer/poly alpha (durasyn) olefin blend RICON 100polybutadien Ricon Resins RICON 184 polybutadien Ricon Resins 30 45 45RICON 134 polybutadien Ricon Resins NIPOL 1312 butadene acryleneamineZeon Chemical 30 30 copoymer TRILENE 65 ethylene propylene Uniroyalcopolymer KRATON 1203 ethylene butylene Shell polymer KRATON 207ethylene butylene Shell polymer VITON A-100 flouroelastomer Dupont DowCURABLES CN 111 epoxidized soy bean oil Sartomer 29.22 29.22 29.22 58.4458.44 58.44 33 28 acrylate CL 1039 urethane monoacrylate UCB Radcure 10OILS/PLASTICIZERS DURASYN/P104 3:2 poly alpha olefin/ Arizona Chemical25 25 phenolic resin blend (P104) P 550 polyester glutamate C. P. Hall20 10 10 10 SF96-350 silicone fluid GE Silicones PHOTOINITIATORSIRGACURE 819 trimethylbenzoyl- Ciba 2.19 2.19 2.19 4.38 4.38 4.38phenylphosphineoxide DAROCURE 1173 hydroxymethylphenyl- Ciba 1.61 1.611.61 3.22 3.22 3.22 propanone IRGACURE 184 hydroxycyclohexyl- Ciba 0.580.58 0.58 1.16 1.16 1.16 phenylketone IRGACURE 500 1:1hydroxycyclohexyl- Ciba 8 8 phenylketone/ benzophenone blend ADDITIVESLICA 44 neopentyl[diallyl]oxy, Kenrich Petro- 1 tri(N-ethylenediamino)-chemical ethylzirconate TEXOPHOR anionic surfactant Henkel 2 2 2 2 2 2SPECIAL IRGACOR 153 succinic acid amine Ciba 4.5 salt TINUVIN 292hindered amine Ciba 5 5 ANTIOXIDANT IRGANOX 1010 hindered phenolic Ciba0.96 0.96 0.96 1.92 1.92 1.92 0.67 1.13 CORROSION H-600 calcium silicateHuber 10 10 10 10 10 10 9 9 CONTROL LITHIUM lithium stearate Reagens 5 55 5 5 4 6 6 STEARATE BN ZPG boron nitride ZYP Coatings PIGMENT RUTILER900 TiO₂ Dupont 0.44 0.44 0.44 0.88 0.88 0.88 1.33 0.57 VISCOSITYGILSONITE hydrocarbon resin Lexco 4 4 4 4 4 4 4 CONTROL/MISC. PKHP 200phenoxy resin Phenoxy Special- 4 ists FILLERS NYAD G wallastonite Nyco 2TS 610 treated fumed silica Cabot 0 0 0 4 0 0 BARAGEL 10 bentonite clayElementis 4 4 3 4 F30D micropheres Pierce & Stevens TOTAL 106 101 105.5105 103 104 128 132.7 SAMPLE NO. 25 26 27 28 29 30 31 32 RESIN/RUBBERLUCANT 2000 ethylene alpha olefin Mitsui Chemical LUCANT 600 ethylenealpha olefin Mitsui Chemical 30 RICON 131 5MA maleinized poybutadieneRicon Resins TRILENE 65/ 1:1 ethylene propylene Amoco DURASYNcopolymer/poly alpha (durasyn) olefin blend RICON 100 polybutadien RiconResins RICON 184 polybutadien Ricon Resins RICON 134 polybutadien RiconResins 20 25 35 25 10 NIPOL 1312 butadene acryleneamine Zeon Chemicalcopoymer TRILENE 65 ethylene propylene Uniroyal 10 copolymer KRATON 1203ethylene butylene Shell 25 polymer KRATON 207 ethylene butylene Shellpolymer VITON A-100 flouroelastomer Dupont Dow 10 CURABLES CN 111epoxilized soy bean oil Sartomer 33 33 61 61 42.5 33 42.5 49 acrylate CL1039 urethane monoacrylate UCB Radcure OILS/PLASTICIZERS DURASYN/P1043:2 poly alpha olefin/ Arizona Chemical 20 phenolic resin blend (P104) P550 polyester glutamate C. P. Hall SF96-350 silicone fluid GE SiliconesPHOTOINITIATORS IRGACURE 819 trimethylbenzoyl- Ciba phenylphosphineoxideDAROCURE 1173 hydroxymethylphenyl- Ciba propanone IRGACURE 184hydroxycyclohexyl- Ciba phenylketone IRGACURE 500 1:1 hydroxycyclohexyl-Ciba 10 10 18 18 12 10 10 13 phenylketone/ benzophenone blend ADDITIVESLICA 44 neopentyl[diallyl]oxy, Kenrich Petro- tri(N-ethylenediamino)-chemical octylzirconate TEXOPHOR anionic surfactant Henkel SPECIALIRGACOR 153 succinic acid amine Ciba 45 5 5 4 salt TINUVIN 292 hinderedamine Ciba ANTIOXIDANT IRGANOX 1010 hindered phenolic Ciba 1.17 0.67 1.51.5 0.8 0.67 0.8 1 CORROSION H-600 calcium silicate Huber 9 9 8 9 8 8 84 CONTROL LITHIUM lithium stearate Reagens 5 6 8 6 6 6 6 2 STEARATE BNZPG boron nitride ZYP Coatings PIGMENT RUTILE R900 TiO₂ Dupont 1.33 1.332.5 2.5 1.7 1.33 1.7 1 VISCOSITY GILSONITE hydrocarbon resin Lexco 4 4CONTROL/MISC. PKHP 200 phenoxy resin Phenoxy Special- ists FILLERS NYADG wallastonite Nyco TS 610 treated fumed silica Cabot BARAGEL 10bentonite clay Elementis 2 2 6 5.5 2 2 3 4 F30D micropheres Pierce &Stevens 0.5 TOTAL 116 115 103 102.5 98 101 102 108 MIXING: ALL BATCHESWERE MIXED USING A COWLES DISPERSER. ALL LIQUIDS WERE ADDED FIRST,BLENDED THEN HEATED BETWEEN 120 AND 180 F.. POWDERS WERE THEN ADDED WITHA FINAL BLENDING TAKING 20 MINUTES. TOTAL BATCH MIX TIME LESS THAN 1HOUR.

EXAMPLE 42

This Example illustrates formation of the inventive compositions in theform of an aerosol spray. The components of the spray are listed below:

COMPONENT NAME AMOUNT SUPPLIER Polybutene Oil H-50 61%  Amaco LinseedOil OKO S-70 5% Epoxy Resin Epon SU 2.5 15%  Shell Fumed Silica CabosilTS-720 5% Cabot Calcium Silicate Hubersorb 600 8% Huber Li Stearate 6%Witco

The composition was blended in accordance with Example 7, diluted 50%with naphtha and placed into an aerosol can at loading of 33% of A-31(A-46 can also be used as a propellant).

The aerosol composition was sprayed at a thickness of 0.02 inch upon asteel panel and tested in accordance with ASTM B-117. The formula waspassed the ASTM B-117 test for at least 24 hours.

What is claimed is:
 1. A composition comprising a combinationcomprising: at least one synthetic base oil, at least one polymer thatis at least partially miscible with said at least one base oil, at leastone silica containing material in an amount effective to thicken thecomposition.
 2. The composition of claim 1 wherein the silica containingmaterial comprises silicon dioxide.
 3. The composition of claim 1wherein the silica containing material comprises at least one memberchosen from the group of calcium silicate, potassium silicate and sodiumsilicate.
 4. The composition of claim 1 further comprising an additiveselected chosen from the group of polyethylene, polyvinylidenedifluoride, polytetrafluoroethylene, polyvinyl fluoride, phosphateesters, dithiophospahates, dithiocarbonates, calcium carbonate, zincstearate, ammonium molybdate, chlorinated paraffins, graphite,molybolenum disulfide, tungsten disulfide, zinc oxide, borax, boronnitride, tricresyl phosphate, triphenyl phosphorothionate, fatty acidesters; sulfurized or phospite adducted fatty oils, fatty acids, orfatty acid esters.
 5. The composition of claim 1 further comprising atleast one anti-oxidant chosen from the group of aromatic amines,hindered phenols, diphenylamine, phenyl alpha-naphthylamine,2,6-di-t-butylphenol, phenothiazine, alkylated diphenylamines, alkylatedphenyl alpha-naphthylamines, 2,6-di-t-butyl-p-cresol (BHT), polymericBHT, peroxide decomposers, or a substituted hydroxyphenyl benzotriazole.6. The composition of claim 1 further comprising at least onephotoinitiator.
 7. The composition of claim 1 further comprising anamount of at least one propellant effective to form an aerosol spray. 8.The composition of claim 7 wherein said base oil comprises polybuteneoil, said polymer comprises an epoxy, said thickener comprises calciumsilicate, said propellant comprises at least one hydrocarbon and furthercomprising at least one solvent.
 9. The composition of claim 6 whereinsaid at least one polymer comprises at least one member chosen from thegroup of polybutadiene, ethylene propylene copolymer and afluoroelastomer.
 10. The composition of claim 6 wherein the base oilcomprises at least one member chosen from the group of silicone oil,polyalphaolefin and polyester glutarate.
 11. The composition of claim 6further comprising at least one of epoxidized soybean oil and urethanemonoacrylate.
 12. The composition of claim 6 further comprising titaniumdioxide and at least one member chosen from the group of calciumsilicate, potassium silicate and sodium silicate.
 13. The composition ofclaim 1 further comprising at least one member chosen from the group ofgilsonite, bentonite clay, silica and wallastonite.
 14. A compositioncomprising a combination comprising: at least one synthetic base oil, atleast one polymer that is at least partially miscible with said at leastone base oil, at one thickener comprising an effective amount of atleast one silica containing material, and; at least one photoinitator.15. The composition of claim 14 comprising a combination comprisingethylene alpha olefin, epoxidized soy bean oil, at least one thickenerand at least one photoiniator.
 16. The composition of claim 14comprising a combination comprising polybutadiene, epoxidized soy beanoil, at least one thickener and at least one photoiniator.
 17. Thecomposition of claim 15 further comprising urethane monoacrylate. 18.The composition of claim 14 comprising a combination comprisingbutadiene acrylonitrile copolymer, epoxidized soy bean oil, at least onethickener and at least one photoiniator.
 19. The composition of claim 14comprising a combination comprising polybutene oil, linseed oil, epoxyresin and at least one thickener.
 20. The composition of claim 1 furthercomprising at least one member selected from the group consisting ofsoap greases, soap complexed greases and mineral oil greases, vegetableoil based greases, organo-clay greases, plyurea greases, and polyureacomplexed greases.